Cooper Turbocompressor Turbo Air 3000 User manual

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

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Contents
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About This Manual
About This Manual
This manual contains the basic information necessary for using and maintaining the Turbo Air 3000®
Oil Free Centrifugal Compressor, from the original startup and operation to inspection and servicing.
However, since installations may vary, these instructions may not cover all details or variations in the
equipment supplied or every question which may possibly arise during use.
If a question or situation develops which is not answered directly in this manual, contact an authorized
Cooper Turbocompressor sales or service representative for more information, or contact the factory
directly for specific answers and/or advice.
All operating personnel should become familiar with the contents of this manual before the compressor
is put into service. This is particularly important with regard to the safety precautions listed in the
Introduction and those included at relevant points of the procedures described in other sections of
this manual.
WARNING:
Read, be sure to clearly and completely understand, and then carefully follow all the
directions included in this manual. Failure to adhere to the guidelines and specific
instructions provided could cause equipment damage and/or serious personal injury
or death.

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Contents
Table of Contents
About This Manual iii
Section One: Introduction
About Cooper Turbocompressor 1— 3
The Turbo Air Centrifugal Compressor 1— 4
Safety Precautions 1— 6
Safety Labels 1— 7
Warranty 1—10
Limitation on Liability 1—11
Unauthorized Repair 1—11
SectionTwo: Specifications
General Compressor Specifications 2— 3
Compressor Lubricant Requirements 2— 6
Section Three: The Control System
The Vantage Control Panel 3— 3
The Vantage User Interface 3— 4
Input or Operational Keys 3— 8
Pratice Exercise 3— 9
Section Four: Routine Operation
General Considerations 4— 3
The Operating Data Record 4— 3
Routine Startup 4— 5
Routine Shutdown 4— 6
Adjusting the System Pressure Setpoint 4— 7
Section Five: Maintenance
General Considerations 5— 3
DailyInspection 5— 4
Scheduled Maintenance 5— 5
Professional Inspection 5— 6
Filter Maintenance 5— 7
Lubrication 5—11
Additional Maintenance Procedures 5—17
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
Section Six: Troubleshooting
General Considerations 6— 3
How to Use the Troubleshooting Guide 6— 4
How to Request Assistance 6— 5
Alarm and Trip Functions 6— 6
Drive Train Troubleshooting 6— 8
Control System Troubleshooting 6—10
Air System Troubleshooting 6—12
Lubrication System Troubleshooting 6—13
Section Seven: Parts and Service
Aftermarket Support 7— 3
Parts Ordering Procedure 7— 4
PartsAvailability 7— 4
The Return Goods Policy 7— 4
The Periodic Maintenance Parts Inventory 7— 5
The Professional Inspection Parts Requirement 7— 7
Control System Parts 7— 9
Lubrication System Parts 7—12
Main Drive Coupling Parts 7—14
Heat Exchanger Parts 7—15
Air Piping Parts 7—18
Appendix A: Installation
General Considerations A— 3
The Installation Work Schedule A— 4
Labor, Supplies, Equipment and Tools A— 5
Site Considerations A— 6
Process Air Piping A— 8
Utility Piping A—19
Electrical Interface A—27
Receiving, Lifting, Moving, and Bolting A—30
Preparing for Startup A—32
Preventing Startup Problems A—37
The Inspection Prior to Initial Startup Schedule A—38
The Initial Startup Procedure A—40
Service Assistance A—41
Appendix B: The Lubrication System
General Considerations B— 3
The Compressor Lubrication System B— 4
Vantage Control of Compressor Lubrication B— 5
Operational Guidelines B— 6
Gearbox and Reservoir Venting B— 7
Optional Features B— 8
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Contents
Appendix C: Vantage Control System Logic
General Considerations C— 3
Compressor Control Methods C— 4
AUTO-OFFLINE Control C— 7
AUTO-STANDBY Control C—10
AUTO-UNLOAD Control C—12
Compressor Safety Mechanisms C—14
Appendix D: Control System Setpoints Adjustments
General Considerations D— 3
The Operation Setpoint Adjustment Procedure D— 4
Minimum Amp Setpoint Adjustment D— 7
The Protection Setpoint Adjustment Procedure D—11
Appendix E: Control System Initialization
General Considerations E— 3
Control System Initialization E— 4
Analog Channel Initialization E—15
Factory Default Initialization E—23
Appendix F: Glossary
Contract Drawings
Supplemental Data
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Introduction
1—1
Section One
Introduction
In this section, the reader will learn about:
¨Cooper Turbocompressor
¨The Turbo Air 3000 Centrifugal
Compressor
¨Safety Precautions
¨Safety Labels
¨Warranty
¨Limitation on Liability
¨Unauthorized Repair

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Introduction
1—3
About Cooper Turbocompressor
Cooper Turbocompressor’s reputation as a worldwide leader in the design and manufacture of high
technology centrifugal compressors is based upon an engineering tradition that spans over four
decades.
This tradition of technological innovation and leadership began in 1955, when the former Joy
Manufacturing Company developed the first integrally geared centrifugal compressor. In time, the
Joy Manufacturing Company grew and eventually emerged as Cooper Turbocompressor. The original
machine developed in those early years became the prototype for the ingenious design that continues
to be the defining standard for oil-free centrifugal compressors.
The dependability, efficiency, and adaptability of its product line have established Cooper
Turbocompressor as a global leader in the production of high technology centrifugal compressors.
From the early MSG model through the C-8 model to the recent Enhanced Turbo Air 2000 Compressor
and the Turbo Air 3000 Compressor, these compressors are known for their ease of automation and
high operating reliability. Cooper Turbocompressor centrifugal compressors operate in a diverse array of
installations that spans six continents. International concern for a cleaner environment has also moti-
vated users to choose these Cooper Turbocompressor products, which allow them to harness the
power of oil-free compressed air as well as to minimize the ratio of energy consumption required.
The Buffalo, New York, USA, dedicated complex includes the home office, the manufacturing plant, a
state-of-the-art research and development facility and the training school. These resources, along with
a worldwide network of sales distributors and trained and authorized service representatives, enable
Cooper Turbocompressor, Inc. to provide the very best products and service to those industries which
have come to rely on Cooper Turbocompressor centrifugal compressors.
Cooper Turbocompressor is ISO 9001 Certified.
To learn more, look us up on the Internet:
Http//www.turbocompressor.com
Figure 1—1 The Buffalo, New York, USA, Home Office and Centralized Facilities

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The Turbo Air 3000 Centrifugal Compressor
The Turbo Air 3000 Centrifugal Compressor is a state of the art source of oil-free air manufactured with
the user’s needs in mind. The simple but rugged mechanical design provides many advantages. It
combines the best features of aerodynamic technology to achieve optimum energy efficiency, and it
delivers lower horsepower to cubic feet per minute (CFM) ratios than any other oil-free centrifugal
compressor available.
The Most Advanced
Compressor Components Available
The Turbo Air 3000 Compressor includes internal components which are unique to the industry. Supe-
rior pinion bearings designed for unlimited life and operation at any load. Non-contacting, non-
wearing labyrinth air and oil seals that require no buffering to ensure oil-free compressed air. Impellers
that are an advanced design which combines the best features of a sigma-radial impeller and a back-
ward-leaning impeller. Vaned diffusers that are matched to the impellers for incomparable efficiency.
Finally, inlet guide vanes that are mounted close to the impeller to achieve maximum benefit.
The Vantage Control System
The Vantage control system is standard on the Turbo Air Compressor package. Vantage provides the
compressor owner with high performance solutions through faster response times, improved reliability
and reduced energy costs over other OEM or PLC controllers. This state-of-the-art system is compatible
with all other centrifugal, reciprocating, and rotary screw compressors. The Vantage system was
developed as a result of a strategic alliance formed between Cooper Turbocompressor and Bay Con-
trols.
The various control modes available provide optimal efficiency in even the most demanding applica-
tions, or, when necessary, maintain air system pressure at a uniform level.
NOTE: The Turbo Air 3000 Compressor package is not a complete, stand-alone compressed air
system. To complete the system, additional components (such as main drive motor starter, oil pump
starter, manifolds, inlet air filters, silencers, expansion joints, etc.) are also required. Cooper
Turbocompressor offers a selection of optional equipment as part of the package or as add-ons after
installation.

Introduction
1—5
Other Design Features
Other outstanding design features of the Turbo Air 3000 compressor are shown in Figure 1—2
including:
1. Horizontally split gearbox casing
2. Built-in aftercooler
3. Built-in intercoolers
4. Mounted control panel
5. Self-contained lubrication system
6. Inlet guide vanes (standard)
7. Shaft-driven main oil pump
8. Mounted water manifold (optional)
9. Mounted bypass valve (optional)
Figure 1—2 The Turbo Air 3000 Centrifugal Compressor
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3
4
5
6
7
8
9
3

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Safety Precautions
The Turbo Air 3000 Centrifugal Compressor is a powerful industrial machine that utilizes high-speed
rotating elements and high voltages to produce high air pressures. Therefore, it is very important to
use common sense and extra safety precautions whenever it is in operation as well as when performing
maintenance or making repairs.
Cooper Turbocompressor expressly disclaims responsibility or liability for any injury or damage
caused by failure to observe specified or other common safety precautions or failure to exercise
ordinary caution, common sense, and due care required in operating the compressor even though
not specified herein.
The alert messages shown here appears throughout this manual to indicate those situations and times
when special care is necessary to prevent component harm or personal injury. There are three degrees
of urgency:
CAUTION:
This indicates that there may be the possibility of minor equipment damage.
WARNING:
This indicates that there could be the possibility of minor equipment damage
or personal injury.
DANGER:
This indicates that there will definitely be major equipment damage and/or personal injury
or death if all proper safety precautions are not carefully followed.
The safety guidelines included here are also included on the safety labels affixed to various parts of the
compressor. They alert the user to possible and probable hazards and serve to remind the user of
specific safety precautions. Before using the Turbo Air 3000 Centrifugal Compressor, be certain to
review the safety labels and the following safety guidelines.
WARNING:
Observe all safety precautions included in this manual and on the compressor safety labels.
Failure to do so may cause equipment damage and/or personal injury.

Introduction
1—7
Safety Labels
WARNING
HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY
OR DEATH
Disconnect all power supplies, lock-out and display
signs before servicing equipment.
DANGER
AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY
OR DEATH
DO NOT operate the compressor at pressure in excess of
the nameplate rating.
Close the discharge block valve and relieve system of
pressure before removing any caps or plugs, or servicing
compressor.
DO NOT play with compressed air.
Wear eye protection when using compressed air.
CAUTION
ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE
DEATH.
All electrical enclosures and components must be installed
and grounded in accordance with the National Electric Code
and other local codes.

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Safety Labels
WARNING
HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.
Some surfaces of the compressor and motor have excessive
temperatures. To avoid burns, keep hands and other body
parts away while unit is operating.
DANGER
HOT OIL UNDER PRESSURE. WILL CAUSE SEVERE
INJURY OR DEATH.
Shut down compressor and pumps before removing any
caps or plugs, or servicing any parts.
DANGER
DO NOT USE DISCHARGE AIR FOR BREATHING OR
FOOD PROCESSING, AS IT WILL CAUSE SEVERE INJURY
OR DEATH.
Air from the compressor used for these processes in the U.S.A.
must meet OSHA 29 CFR 1910 or FDS 21 CFR 178.3570 filtra-
tion regulations.
CAUTION
ELECTRICAL OR CONTROL HAZARD. COULD CAUSE
INJURY OR MACHINERY DAMAGE.
DO NOT rewire or place jumpers in the control panel without
written consent from the Cooper Engineering or Service Depart-
ments.
Periodically check all safety devices for proper operation.

Introduction
1—9
Safety Labels
WARNING
ROTATING SHAFTS COULD CAUSE SEVERE INJURY
OR DEATH.
DO NOT remove protective guards while the compressor is
in operation.
DO NOT attempt to service any part while the machine is
operating.
WARNING
UNIT CAN AUTOMATICALLY RESTART CAUSING
SEVERE INJURY OR DEATH.
Before removing the gearbox cover, lock the main power
OFF, close the system block valve, turn the lube pump OFF,
and remove the drive coupling.
CAUTION
Exercise cleanliness during maintenance and when
making repairs. Keep dirt away by covering parts and
exposed openings with a clean cloth.
Be sure no tools, rags, or loose parts are left on the com-
pressor or drive parts.
DO NOT use flammable solvents for cleaning parts.
WARNING
DO NOT operate the compressor in areas where there is a
possibility of ingesting flammable or toxic fumes.

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Warranty
Cooper Turbocompressor warrants that the compressor supplied conforms to applicable drawings and
specifications and that the compressor will be free from defects in material or workmanship for a
period of twelve (12) months from the date of initial operation or a period of fifteen (15) months from
the date of shipment, whichever period expires first.
If, within that period, Cooper Turbocompressor receives written notice from the purchaser of any
alleged defect in or nonconformance of the compressor and if, in Cooper Turbocompressor’s judg-
ment, the compressor does not conform to the original specifications or is found to be defective in
material or workmanship, at its option Cooper Turbocompressor will make restitution in one of these
ways:
1. By furnishing a service representative to correct the defective workmanship.
2. By repairing or replacing the component upon the component having been returned FOB to the
Cooper Turbocompressor factory in Buffalo, New York, USA.
3. By returning the full purchase price of the compressor (without interest) to the purchaser.
Cooper Turbocompressor’s sole responsibility and the purchaser’s exclusive remedy hereunder is
limited to such repair, replacement, or repayment of the full purchase price.
Equipment and accessories furnished by third parties that are not incorporated in the compressor
package manufactured by Cooper Turbocompressor are warranted only to the extent of the original
manufacturer’s warranty to Cooper Turbocompressor.
There are no other warranties—express, statutory, or implied—including those of merchantability
and/or fitness for purpose. Moreover, there is no affirmation of fact or representation that extends
beyond the description of the face of this warranty.
This warranty shall be void and Cooper Turbocompressor shall have no responsibility to repair, replace,
or repay the purchase price of defective or damaged compressors or component parts resulting directly
or indirectly from:
1. The purchaser’s use of repair or replacement parts or supplies not of Cooper Turbocompressor’s
manufacture or which have not been recommended by Cooper Turbocompressor.
2. The purchaser’s failure to store, install, operate, and maintain the compressor according to Cooper
Turbocompressor’s written specifications, drawings, and good engineering practice.

Introduction
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Limitation on Liability
Cooper Turbocompressor’s total responsibility for any claims, damages, losses, or liabilities arising out of
or related to the performance of the products covered hereunder shall not exceed the original pur-
chase price.
In no event shall Cooper Turbocompressor be liable for any special, indirect, incidental, or consequen-
tial damages of any character, including but not limited to:
1. Loss of use of productive facilities or equipment.
2. Lost profits, property damage, and/or expenses incurred in reliance on Cooper Turbocompressor’s
performance hereunder.
3. Lost production, whether suffered by the purchaser or any other third party.
Cooper Turbocompressor disclaims all liability for any and all costs, claims, demands, expenses, or
other damages, either direct or indirect, incident to all property damage arising out of any cause of
action based on strict liability.
Unauthorized Repair
In the event that the owner allows the compressor to be serviced or repaired by unauthorized
personnel, the coverage of the original warranty policy will be automatically terminated.

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