Troubleshooting Guide

CENTAC
Troubleshooting Guide
INGERSOLL-RAND
AIR COMPRESSORS
CENTAC TROUBLESHOOTING GUIDE
Copyright Notice
Copyright 1996-1997 Ingersoll-Rand Company THE CONTENTS OF THIS MANUAL ARE PROVIDED AS IS AND WITHOUT ANY IMPLIED WARRANTIES WHATSOEVER.
Ingersoll-Rand 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.
CST-TP0007 1994 Ingersoll-Rand Company Date of issue: January, 1999 Supersedes: 16-Dec-94
Table of Contents
Surge______________________________________________________________________ 1 Low Seal Air Pressure________________________________________________________ 2 Low System Air Pressure _____________________________________________________ 3 High Vibration ______________________________________________________________ 4 Low Control Air Pressure _____________________________________________________ 5 Low Instrument Air Pressure __________________________________________________ 5 Failure to Start ______________________________________________________________ 6 No Control Power ___________________________________________________________ 7 Failure to Load ______________________________________________________________ 7 Low Oil Pressure ____________________________________________________________ 8 High Oil Temperature ________________________________________________________ 9 High Air Temperature _______________________________________________________ 10 Common Conversions and Information ________________________________________ 11 1. Temperature __________________________________________________________ 11 2. Pressure gauge ______________________________________________________ 11 2. Pressure gauge, continued ____________________________________________ 12 3. Length _______________________________________________________________ 12 4. Flow_________________________________________________________________ 13 5. Volume ______________________________________________________________ 13 6. Electrical _____________________________________________________________ 14 6. Electrical, continued ___________________________________________________ 15 7. Vibration _____________________________________________________________ 16 8. Water Quality Requirements_____________________________________________ 17
CST-TP0007 1994 Ingersoll-Rand Company Date of issue: January, 1999 Supersedes: 16-dec-94
Surge
Cause 1. Dirty inlet air filter. Replace filter. Replace pipe. Investigate. Check to see what is necessary to lower air temperatures. Check water temperature, water flow, water pressure, etc. Investigate. Check to see if it is possible to lower water temperature. Lower setpoint. Lower setpoint. Adjust or replace. Increase CLL or LLR setting. Increase P1, PR3 or adjust mechanical stop. Calibrate as necessary. Repair or replace. Investigate. Take necessary steps to correct restriction. Check for closed block valve or excessive dryer pressure drop. Clean air coolers. Clean impeller. Clean diffuser. Reset clearance. Replace. Replace pin. Repair or replace. Solution
2. Too small inlet pipe (remote-mounted air filter). 3. High interstage air temperatures.
4. Increase in water temperature. 5. Increase in inlet air temperature. 6. Setpoint higher than design discharge pressure of compressor. 7. Defective system pressure controller. 8. Too low CLL or LLR (throttle surge). 9. Too low P1, PR3, or mechanical stop adjustment (unloaded surge). 10. Improper calibration of valve I/P, positioner, or actuator. 11. Defective bypass valve. 12. Restriction in customer's system.
13. Restricted air flow through air coolers. 14. Dirt build-up on impeller vanes. 15. Blockage of diffuser air passage. 16. Improper wheel clearance. 17. Worn or damaged impeller. 18. Butterfly valve pin broken. 19. Discharge check valve hanging up.
Low Seal Air Pressure

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

Cause 1. Incorrect setpoint. 2. Incorrect valve calibration. 3. Bad controller. 4. Dirty inlet filter. 5. Compressor operating unloaded. 6. System demand greater than compressor capacity. Adjust. Restroke valves. Repair or replace. Replace filter elements. Switch selector switch to load. Check for excessive air usage like open valves, leaking fittings, etc., and correct. Start additional compressor. Recommend that customer purchase another Centac if additional capacity is required. Open valve. Adjust controls. Repair or replace. Relocate control air connection Investigate and correct. Increase setting (Do not exceed FLA+SF). Investigate and correct. Replace seat; free up sticking valve. Lower CLL to activate bypass valve on MP3 panel. Ensure 2TR is operating properly on Electro-Pneumatic panel. Solution
7. Compressor block valve closed. 8. Incorrect controls calibration. 9. Discharge check valve sticking. 10. System air pressure sensing point in wrong location. 11. Excessive pressure differential across air dryer. 12. Too low CLH setting. 13. Leaking bypass valve. 14. Bypass valve stays open; inlet valve functions normally.
High Vibration
Cause 1. Low oil temperature. Solution Increase oil temperature by adjusting oil heater thermostat. Close cooling water valves to oil cooler. Circulate oil. Reduce pressure. Adjust main oil pump pressure relief valve with oil at operating temperature. Investigate and correct. Check for restriction, improper venting, too high oil level. Realign coupling. Replace. Remove excessive grease. Replace. Have motor rotor balanced. Replace. Replace rotor assembly or necessary parts. Clean and balance rotor assembly. Remove pipe strain. Replace with correct oil. Replace. Investigate and correct. Check for restriction in condensate drainage system. Investigate and correct. Ensure oil supply groove in plain bearing shell is aligned properly with oil supply hole through casing.
2. High oil pressure.
3. Oil not draining properly from bearings. 4. Incorrect coupling alignment. 5. Worn coupling. 6. Excessive grease in coupling. 7. Bad bullgear or intermediate gear bearings. 8. Unbalanced motor rotor. 9. Bad motor bearings. 10. Worn rotor assembly parts. 11. Excessive build-up on impellers. 12. Excessive pipe strain. 13. Incorrect type of oil. 14. Bad rotor assembly bearings or seals. 15. Excessive moisture carryover.
16. Inadequate oil supply to plain bearing.
Low Control Air Pressure

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

Cause 1. Instrument air line too small. 2. Instrument air dryer malfunctioning. 3. Instrument air valve closed. 4. Instrument air supply pressure below recommended pressure. 5. Dirty I.A. filter. 6. I.A. filter wrong size. 7. Leaking fittings or damaged pipe. Solution Replace with a larger pipe. Repair or replace. Open valve. Increase supply pressure. Obtain a different air source of adequate pressure. Clean or replace. Replace. Repair or replace.
Failure to Start
Cause 1. No power to motor starter. 2. Blown fuse. 3. STOP button pushed in. 4. Overloads tripped. Energize power. Replace blown fuse. Pull out STOP button. Reset overloads. (If trip occurs do not reset find cause of trip) Investigate and correct. Mechanical linkage out of adjustment. Bad 2M contactor. Replace or repair contactor. Investigate and correct. Adjust mechanical interlocks. Repair or replace. Tighten and/or clean as necessary. Replace. Investigate. Increase voltage supply. Increase wire size. Increase breaker size. Ground neutral at transformer. Check wiring. Investigate and correct. Solution
5. Control wiring incorrect. 6. Trips at transition.
7. Interlocks not satisfied. 8. Bad motor starter. 9. Loose or corroded wiring. 10. Control relay defective. 11. Low voltage. 12. Control circuit not grounded properly. 13. Wiring to remote starter incorrect.
No Control Power
Cause 1. POWER ON selector switch OFF. 2. Blown fuse. 3. Bad control power transformer. 4. Control power transformer wired incorrectly. Solution Turn POWER ON switch to ON. Replace fuse. Replace. Correct transformer wiring.
Failure to Load
Cause 1. LOAD selector switch in the wrong position. 2. Inlet valve stuck. 3. Controller setpoint too low. 4. No control air signal. 5. Surge sensor tripped. 6. Bypass valve will not close. 7. No power air to inlet or bypass valve. 8. Valve actuator or positioner malfunctioning. 9. REMOTE/LOCAL switch for CEM in wrong position. 10. Incorrect CLL setting. Solution Turn switch to LOAD. Investigate and correct. Adjust. Investigate and correct. Check for closed valve. Adjust or replace. Investigate and correct. Investigate. Open power air shutoff valve. Repair or replace. Turn to REMOTE for CEM operation. Reset to correct value.
Low Oil Pressure

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

Cause 1. Inadequate water flow. 2. High water temperature. 3. Bad AMOT valve. 4. Water control valve thermostat out of calibration. 5. Dirty oil cooler on water side. 6. Incorrect oil. 7. Water/glycol mixture greater than 50/50. 8. Water temperature supply higher than oil cooler design. 9. Heat exchanger radiating fins dirty. 10. Incorrect number of water passes. Solution Provide adequate water flow to the oil cooler. Lower water temperature; use a cooler water source. Replace. Calibrate controller. Clean water side of oil cooler. Check oil specification against I-R oil requirements; install correct oil. Adjust mixture to ensure the glycol is not greater than 50%. Install larger oil cooler or additional cooler. Clean fins. Investigate. Orient return bonnett correctly; replace bonnett gasket if bypassing; install cooler with more passes.
10
High Air Temperature

Cause 1. Inadequate water flow. 2. High water temperature. 3. Water control valve thermostat out of calibration. 4. Plugged water passages or scale on the tubes. 5. Water flow bypassing air cooler. Solution Provide adequate water flow to the air cooler; adjust water flow to the air cooler. Lower water temperature; use a cooler water source. Calibrate controller. Clean water side of 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. 7. Heat exchanger radiating fins dirty. 8. Water flows backward. Cold water inlet on cooler hot air inlet side is backwards flow. 9. Air cooler oriented incorrectly. Adjust mixture to ensure the glycol is not greater than 50%. Clean fins. Investigate. Repipe if water piping is backwards; switch backflush valve to correct position. Remove air cooler and rotate to align the water ports correctly with the water connections of the casing.
11
Common Conversions and Information

1. Temperature
Fahrenheit to Celsius Celsius to Fahrenheit C = 5/9 (F-32) F = 9/5C + 32
2.
Pressure gauge
PSI to Atmosphere PSI to inches of H2O at 68F PSI to inches of mercury (in Hg) at 0C PSI to kPa PSI to Kg/cm
2 2 2 2 2 2
PSI X 0.06805 PSI X 27.73 PSI X 2.036 PSI X 6.8948 PSI X 0.07031 Kg/cm X 0.9678 Kg/cm X 0.98066 Kg/cm X 28.96 Kg/cm X 98.066 Kg/cm X 14.223 kPa X 0.145 bars X 14.504 in H2O X 0.07342 in H2O X 0.03606 in H2O X 0.2487
2 2 2 2 2 2
Kg/cm to Atmosphere Kg/cm to bars Kg/cm to inches of mercury (in Hg) at 0C Kg/cm to kPa Kg/cm to PSI kPa to PSI bars to PSI inches of H2O at 68F to inches of mercury (in Hg) at 0C inches of water at 68F to psi inches of water at 68F to kPa inches of water at 68F to Kg/ cm inches of water at 68F to bar inches of water at 68F to standard atmosphere (atm) inches of mercury at 0C to inches of water at 68F inches of mercury at 0C to psi inches of mercury at 0C to kPa
in H2O X 0.002535 in H2O X 0.002487 in H2O X 0.002454 in Hg X 13.62 in Hg X 0.03606 in Hg X 3.3864
12
2.
Pressure gauge, continued

inches of mercury at 0C to Kg/cm inches of mercury at 0C to bar inches of mercury at 0C to standard atmospheres (atm) atmosphere (standard) to bar atmosphere (standard) to psi atmosphere (standard) to Kg/cm atmosphere (standard) to Kg/m atmosphere (standard) to kPa
2 2 2
in Hg X 0.034532 in Hg X 0.033864 in Hg X 0.03342 atm X 1.01325 atm X 14.696 atm X 1.0332 atm X 10332 atm X 101.325
3.
Length
inches to meters (m) inches to centimeters (cm) inches to millimeters (mm) meters to inches (in.) centimeters to inches (in.) millimeters to inches (in.) mills (0.001") to millimeters in. X 0.0254 in. X 2.54 in. X 25.4 m X 39.37 cm X 0.3937 mm X 0.03937 0.001" X 0.0254
13
4.
Flow
cubic feet per minute (scfm) to cubic meters per second (nm /s) cubic feet per minute (scfm) to cubic meters per hour (nm /h) cubic feet per minute (scfm) to cubic centimeters per second 3 (cm /s) cubic feet per minute (scfm) to cubic meters per minute (nm /m) 1000 scfm = 28.32 nm /m cubic meters per hour (nm /h) to cubic meters per minute (scfm) cubic meters per hour (nm /h) to cubic meters per second (nm /s) cubic meters per minute (nm /m) to cubic feet per minute (scfm)
3 gallons per minute (US) to cubic meters per minute (nm /m) 3 3 3 3 3 3 3 3 3
scfm X 0.0004719 scfm X 1.699 scfm X 471.9 scfm X 0.02832
nm /h X 0.016667 nm /h X 0.00027778 nm /m X 35.315 gpm X 0.0037854 gpm X 0.2271 gpm X 8.021 gpm X 0.06309
3 3
gallons per minute (US) to cubic meters per hour (nm /h) gallons per minute (US) to cubic feet per hour (scfh) gallons per minute (US) to liters per second (L/s)
5.
Volume
gallons (US) to cubic inches (in ) gallons (US) to cubic meters (m ) gallons (US) to liters (L) liters (L) to cubic inches (in ) liters (L) to cubic meters (m ) liters (L) to gallons (US) cubic inches (in ) to cubic meters (m ) cubic meters (m ) to cubic inches (in ) cubic meters (m ) to cubic ft. (ft ) cubic feet (ft ) to cubic meters (m )
3 3 3 3 3 3 3 3 3 3 3 3
gal. X 231 gal. X 0.0037854 gal. X 3.7854 L X 61.024 L X 0.001 L X 0.26418 in X (16.387 X 10 6 ) m X 61024 m X 35.315 ft X 0.02832
3 3 3 3 -
14
6.
Electrical
Amps (I) = current Ohm (R) = resistance Watts (W) = electric power Kilowatts (KW) = electric power Kilovolt - amps (kVA) = apparent electric power Kilowatt hour (KW/hr) = unit of electric energy or work performed Joule (J) = metric unit of energy in watt per sec. Volt (E) = unit of electric pressure or electromotive force eff = efficiency (expressed as a decimal) pf = power factor (expressed as a decimal) hp = horsepower output AC = alternating current Ohms Law Relationship (direct current - DC) kw kva Power Factor (pf) =
E=
E = I R
W I
E = WR
W = I 2R
W=
E2 R
W = E I
I=
E R IE 1000 IE 1000
I=
W E
I=
W R
R=
E I
R=
W I2
R=
E2 W
kva = KW = KW =
( single phase AC) (DC)
kva = KW =
1. 73 IE 1000 IE ( pf ) 1000
(3 - phase AC) ( single phase AC)
1. 73 IE ( pf ) 1000
(3 - phase AC)
15
6.
Electrical, continued
hp =
hp =
IE ( eff ) 746
1. 73IE ( eff )( pf ) 746
(DC)
(3- phase AC)
hp =
IE ( eff )( pf ) 746
(single phase AC)
J= J=
IE sec
(DC)
J=
IE ( eff )( pf ) sec
(single phase AC)
1. 73 IE ( eff )( pf ) sec
(3- phase AC)
Amps(hp known) =
Amps (hp known) =
Amps(hp known) =
746( hp) E ( eff )

746( hp) E ( eff )( pf )
(DC)
(single phase AC)
746( hp) 1. 73E ( eff )( pf )
(3- phase AC)
Amps(KW known) =
Amps(KW known) = Amps(KW known) =
Amps(kva known) =
1000 KW E
1000 KW E ( pf ) 1000 KW 1. 73 E ( pf )
(DC)
(single phase AC)
(3- phase AC)
1000 kva E
(single phase AC)
Amps(kva known) =
1000 kva 1. 73 E
(3- phase AC)
16
7.
Vibration
A = Acceleration in g's (in/sec ) = Peak V = Velocity in in/sec = Peak D = Displacement in mils = Peak - Peak f = Frequency in Hz
2
V = 61. 34
A f
V = 0. 0031416 f D
D = 318. 3
V f
D = 19 , 570
A f2
A = 0. 0000511 D f 2
A = 0. 0162 V f
RMS (root mean square) = 0.707 X Peak average = 0.637 X Peak Pk - Pk (Peak to Peak) = 2 X Peak Pk (Peak) = 1.414 X RMS
RMS = 1.111 X average

2
RMS = 0.354 X Pk - Pk average = 0.318 X Pk - Pk Pk - Pk = 3.142 X average
average = 0.900 X RMS Pk - Pk = 2.828 X RMS Pk = 1.571 X average
17
0.707 0.637
+ 0 AVERAGE RMS PEAK
PEAK TO PEAK
in / sec. = mm / sec. 0. 03937 mm / sec. = in / sec. 25. 40
total vibration(in mils) = 1. 25
12000 RPM
8.
Water Quality Requirements

less than 100 PPM less than 50 PPM 140F/60C 6.0 - 8.5 +0.5 - +1.0
Total hardness (expressed as CaCo3) Suspended solids Maximum water temperature (cooler discharge) pH range Langlier saturation index (LI)
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. Rev. C 24 Mar. 1995

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CENTAC

CENTAC TROUBLESHOOTING GUIDE

CENTAC TROUBLESHOOTING GUIDE

CENTAC TROUBLESHOOTING GUIDE

CENTAC TROUBLESHOOTING GUIDE

Low Seal Air Pressure

CENTAC TROUBLESHOOTING GUIDE

Low System Air Pressure

CENTAC TROUBLESHOOTING GUIDE

2. High oil pressure.

16. Inadequate oil supply to plain bearing.

CENTAC TROUBLESHOOTING GUIDE

Low Control Air Pressure

Low Instrument Air Pressure

CENTAC TROUBLESHOOTING GUIDE

5. Control wiring incorrect. 6. Trips at transition.

CENTAC TROUBLESHOOTING GUIDE

CENTAC TROUBLESHOOTING GUIDE

Low Oil Pressure

CENTAC TROUBLESHOOTING GUIDE

High Oil Temperature

CENTAC TROUBLESHOOTING GUIDE

High Air Temperature

CENTAC TROUBLESHOOTING GUIDE

Common Conversions and Information

in H2O X 0.002535 in H2O X 0.002487 in H2O X 0.002454 in Hg X 13.62 in Hg X 0.03606 in Hg X 3.3864

CENTAC TROUBLESHOOTING GUIDE

Pressure gauge, continued

CENTAC TROUBLESHOOTING GUIDE

scfm X 0.0004719 scfm X 1.699 scfm X 471.9 scfm X 0.02832

CENTAC TROUBLESHOOTING GUIDE

( single phase AC) (DC)

(3 - phase AC) ( single phase AC)

CENTAC TROUBLESHOOTING GUIDE

(single phase AC)

(single phase AC)

(3- phase AC)

746( hp) E ( eff )

(single phase AC)

746( hp) 1. 73E ( eff )( pf )

(3- phase AC)

(single phase AC)

(3- phase AC)

(single phase AC)

(3- phase AC)

CENTAC TROUBLESHOOTING GUIDE

RMS = 1.111 X average

RMS = 0.354 X Pk - Pk average = 0.318 X Pk - Pk Pk - Pk = 3.142 X average

average = 0.900 X RMS Pk - Pk = 2.828 X RMS Pk = 1.571 X average

CENTAC TROUBLESHOOTING GUIDE

in / sec. = mm / sec. 0. 03937 mm / sec. = in / sec. 25. 40

total vibration(in mils) = 1. 25

Water Quality Requirements

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