TA 2000 TAC - AAEDR-H-086 Rev 2 PDF

Contents
Compression Systems
Engineering Data Release

AAEDR-H-086
The Turbo Air® Cooled 2000

Centrifugal Compressor
Handbook
Attention:
Upon compressor receipt, it is recommended the
machine be registered at www.c-a-m.com for CCV S M
extended warranty, service information and
updates posted to the web site.
Revision History
Rev. #: 01 ECO# 2164306 February 2007
Rev. #: 02 ECO# 2318415 October 2008
The Turbo Air Cooled 2000 Centrifugal Compressor Handbook
ii
About ThisContents
Manual
About This Manual

This manual contains the basic information necessary for using and maintaining the Turbo Air Cooled
2000® 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
Compression Systems sales or service representative for more information, or contact the factory
directly for specific answers and/or advice.
All operating personnel should become familiar with the contents of this manual before the compressor
is put into service. This is particularly important with regard to the safety precautions listed in the
Introduction and those included at relevant points of the procedures described in other sections of
this manual.
WARNING:
Read, be sure to clearly and completely understand, and then carefully follow all the
directions included in this manual. Failure to adhere to the guidelines and specific instruc-
tions provided could cause equipment damage and/or serious personal injury
or death.
iii
iv
Contents
Table of Contents
About This Manual iii
Section One: Introduction

About Cameron’s Compression Systems 1— 3
The Turbo Air Cooled 2000 Centrifugal Compressor 1— 4
Safety Precautions 1— 6
Safety Labels 1— 7
Warranty 1—10
Limitation on Liability 1—11
Unauthorized Repair 1—11
CC V 5-Year Warranty Program 1—12
Section Two: Specifications

General Compressor Specifications 2— 3
Alarm and Trip Specifications 2— 7
Compressor Lubricant Requirements 2— 8
Section Three: Installation

General Considerations 3— 3
The Installation Work Schedule 3— 4
Site Considerations 3— 6
Process Air Piping 3— 8
Discharge Air Piping 3—11
Utility Piping 3—15
Electrical Interface 3—19
Receiving, Lifting, Moving... 3—22
The Installation Inspection 3—25
Preparing for Startup 3—30
Initial Compressor Startup 3—32
Section Four: Routine Operation

The Operating Data Record 4— 3
Routine Startup 4— 5
Routine Shutdown 4— 6
General Lubrication Considerations 4— 7
The Compressor Lubrication System 4— 8
Operational Guidelines 4— 9
Gearbox and Reservoir Venting 4—10
Optional Features 4—11
v
Section Five: Maintenance

Daily Inspection 5— 4
Scheduled Maintenance 5— 5
Professional Inspection 5— 7
Filter Maintenance 5— 8
Lubrication 5—11
Additional Maintenance Requirements 5—14
Section Six: Troubleshooting

How to Use the Troubleshooting Guide 6— 4
How to Request Assistance 6— 5
Alarm and Trip Functions 6— 6
Drive Train Troubleshooting 6— 7
Control System Troubleshooting 6— 9
Air System Troubleshooting 6—11
Lubrication System Troubleshooting 6—12
Section Seven: Parts and Service

Aftermarket Support 7— 3
Parts Ordering Procedure 7— 4
Parts Availability 7— 4
The Return Goods Policy 7— 4
The Periodic Maintenance Parts Inventory 7— 5
The Professional Inspection Parts Requirement 7— 7
Control System Sensors 7— 9
Lubrication System Parts 7—12
Main Drive Coupling Parts 7—14
Heat Exchanger Parts 7—15
Condensate Drain Parts 7—16
Inlet Filter Parts 7—17
Air Piping Parts 7—18
Controls
Glossary
Contract Drawings
Supplemental Data
vi
Introduction
Section One
Introduction
In this section, the reader will learn about:
♦ About Cameron’s Compression

Systems
♦ The Turbo Air® Cooled 2000

Centrifugal Compressor
♦ Safety Precautions
♦ Safety Labels
♦ Warranty
♦ Limitation on Liability
♦ Unauthorized Repair
♦ CC V 5-Year Warranty Program
1—1
1—2
Introduction
About Cameron’s Compression Systems

Compression Systems’ reputation as a worldwide leader in the design and manufacture of high tech-
nology 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 evolved into Cameron’s Compression Systems. 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 Compression Systems
as a global leader in the production of high technology centrifugal compressors. From the early MSG®
Models through the C-8 Models to the current range of plant air centrifugal compressors, the TURBO
AIR® Series of compressors continue to be known for their ease of automation and high operating
reliability. Compression Systems centrifugal compressors operate in a diverse array of installations that
spans six continents. International concern for a cleaner environment has also motivated users to
choose these Compression Systems 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 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 Compression
Systems to provide the very best products and service to those industries which have come to rely on
Compression Systems centrifugal compressors.
Compression Systems is ISO 9001 and ISO 14001 Certified.
To learn more, look us up on the Internet:

http://www.c-a-m.com
Figure 1—1 The Buffalo, New York, USA, Centralized Facilities
1—3
The Turbo Air® Cooled 2000 Centrifugal Compressor

The Turbo Air Cooled 2000 Centrifugal Compressor is a state-of-the-art source of oil-free compressed air
designed for applications where there is a limited supply or no water available for cooling. The new
Turbo Air Cooled 2000 Compressor makes it possible for industries everywhere to enjoy the features of
centrifugal technology without incurring the added expense of cooling water.
The Turbo Air Cooled 2000 Compressor is the most advanced and complete package available including
integral lubrication and control systems, packaged air-cooled aftercooler, inlet air filter, inlet throttle
valve, bypass valve, and bypass silencer. This compact design requires a minimum of floor space. A
single source of incoming power, connection to the air piping system, and condensate removal piping
are the only external connections required. The option of package mounting the discharge check valve
is also available to further reduce installation cost.
The Most Advanced

Compressor Components Available
The Turbo Air 2000 Compressor includes internal components, which are unique to the industry.
Superior pinion bearings (protected by U.S. patents) that have been designed for unlimited life and
operation at any load. Non-contacting, non-wearing labyrinth air and oil seals that require no buffer-
ing to ensure oil-free compressed air. Impellers that are an advanced design which combines the best
features of a sigma-radial impeller and a backward-leaning impeller. Vaned diffusers that are matched
to the impellers which together produce incomparable aerodynamic efficiencies. Finally, the inlet
throttle valve and the vent valve are electrically operated providing the utmost in control reliability.
The Compressor Control Center

The package-mounted control center provides centralized control of both motor and compressor. The
motor controller components are assembled in various configurations in the lower 3-phase compart-
ment. These include magnetic contactors, oil pump motor starter, oil heater disconnect, current and
control power transformers, fuses and overload relays. The primary incoming terminal block is also
located here. The low-voltage compartment contains components rated at 220 volts maximum, includ-
ing the Maestro Control System display panel and main logic module. The single-point electrical
connection concept is one the more convenient packaging features of the Turbo Air 2000 Compressor.
(When a medium voltage main drive motor is used, the motor controls are located separately and the
power cabling does not pass through the control center.)
The Maestro Control System

The Maestro control system is standard on the Turbo Air Compressor package. Maestro provides the
compressor owner with high performance solutions through faster response times, improved reliability
and reduced energy costs over other OEM or PLC controllers. This state-of-the-art system is compatible
with all other centrifugal, reciprocating, and rotary screw compressors.
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 2000 Compressor package may require additional components such as conden-
sate traps, spare filters, expansion joints, etc. Compression Systems offers a selection of optional
equipment as part of the package or as add-ons after installation.
CAUTION:
The air-to-air heat exchanger fan exhausts as much as 20,000 cubic feet per minute (cfm)
or 34,000 cubic meters per hour (m³/hr), and may exhaust as much as 1,000,000 Btu/hour.
(Refer to Section Three for more information concerning this waste heat.)
1—4
Introduction
Major Component Arrangement
6 1. Horizontally split gearbox casing

5 2. Flange-mounted main drive motor
4 7 3. Electrical control center (pre-
mounted)
4. First Stage air cooler
5. Second Stage air cooler
6. Third Stage air cooler
7. Oil-to-air cooler
8. Blowoff silencer (pre-mounted)
9. Discharge check valve (pre-mounted
optional)
10. Lubrication System
11. Inlet and bypass valves (pre-mounted)
12. Fan housing
13. Inlet air filter (pre-mounted)
3
12
11
1
10
8
13
Figure 1-1 The Turbo Air Cooled 2000 Centrifugal Compressor
1—5
Safety Precautions
The Turbo Air 2000 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.
Compression Systems expressly disclaims responsibility or liability for any injury or damage caused
by failure to observe specified or other common safety precautions or failure to exercise ordinary
caution, common sense, and due care required in operating the compressor even though not
specified herein.
The alert messages shown here appear throughout this manual to indicate those situations and times
when special care is necessary to prevent component harm or personal injury. There are three degrees
of urgency:
CAUTION:
This indicates that there may be the possibility of minor equipment damage.
WARNING:
This indicates that there could be the possibility of minor equipment damage
or personal injury.
DANGER:
This indicates that there will definitely be major equipment damage and/or personal injury
or death if all proper safety precautions are not carefully followed.
The safety guidelines included here are also included on the safety labels affixed to various parts of the
compressor. They alert the user to possible and probable hazards and serve to remind the user of
specific safety precautions. Before using the Turbo Air 2000 Centrifugal Compressor, be certain to
review the safety labels and the following safety guidelines.
WARNING:
Observe all safety precautions included in this manual and on the compressor safety labels.
Failure to do so may cause equipment damage and/or personal injury.
1—6
Introduction
Safety Labels
WARNING
HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY
OR DEATH
Disconnect all power supplies, lock-out and display
signs before servicing equipment.
DANGER
AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY
OR DEATH
DO NOT operate the compressor at pressure in excess of
the nameplate rating.
Close the discharge block valve and relieve system of
pressure before removing any caps or plugs, or servicing
compressor.
DO NOT play with compressed air.
Wear eye protection when using compressed air.
CAUTION
ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE
DEATH.
All electrical enclosures and components must be installed
and grounded in accordance with the National Electric Code
and other local codes.
1—7
Safety Labels
WARNING
HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.
Some surfaces of the compressor and motor have excessive
temperatures. To avoid burns, keep hands and other body
parts away while unit is operating.
DANGER
HOT OIL UNDER PRESSURE. WILL CAUSE SEVERE
INJURY OR DEATH.
Shut down compressor and pumps before removing any
caps or plugs, or servicing any parts.
DANGER
DO NOT USE DISCHARGE AIR FOR BREATHING OR
FOOD PROCESSING, AS IT WILL CAUSE SEVERE INJURY
OR DEATH.
Air from the compressor used for these processes in the U.S.A.
must meet OSHA 29 CFR 1910 or FDS 21 CFR 178.3570 filtra-
tion regulations.
CAUTION
ELECTRICAL OR CONTROL HAZARD. COULD CAUSE
INJURY OR MACHINERY DAMAGE.
DO NOT rewire or place jumpers in the control panel without
written consent from the Compression Systems Engineering or
Service Departments.
Periodically check all safety devices for proper operation.
1—8
Introduction
Safety Labels
WARNING
ROTATING SHAFTS COULD CAUSE SEVERE INJURY
OR DEATH.
DO NOT remove protective guards while the compressor is
in operation.
DO NOT attempt to service any part while the machine is
operating.
WARNING
UNIT CAN AUTOMATICALLY RESTART CAUSING
SEVERE INJURY OR DEATH.
Before removing the gearbox cover, lock the main power
OFF, close the system block valve, turn the lube pump OFF,
and remove the drive coupling.
CAUTION
Exercise cleanliness during maintenance and when
making repairs. Keep dirt away by covering parts and
exposed openings with a clean cloth.
Be sure no tools, rags, or loose parts are left on the com-
pressor or drive parts.
DO NOT use flammable solvents for cleaning parts.
WARNING
DO NOT operate the compressor in areas where there is a
possibility of ingesting flammable or toxic fumes.
1—9
Warranty
Compression Systems 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, Compression Systems receives written notice from the purchaser of any alleged
defect in or nonconformance of the compressor and if, in Compression Systems’ judgment, the com-
pressor does not conform to the original specifications or is found to be defective in material or
workmanship, at its option Compression Systems 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
Compression Systems factory in Buffalo, New York, USA.
3. By returning the full purchase price of the compressor (without interest) to the purchaser.
Compression Systems’ 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 Compression Systems are warranted only to the extent of the original
manufacturer’s warranty to Compression Systems.
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 Compression Systems 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 Compression Systems’ manu-
facture or which have not been recommended by Compression Systems.
2. The purchaser’s failure to store, install, operate, and maintain the compressor according to Com-
pression Systems’ written specifications, drawings, and good engineering practice.
See page 1-12 for information on CCV SM extended warranty program.
1—10
Introduction
Limitation on Liability
Compression Systems’ total responsibility for any claims, damages, losses, or liabilities arising out of or
related to the performance of the products covered hereunder shall not exceed the original purchase
price.
In no event shall Compression Systems be liable for any special, indirect, incidental, or consequential
damages of any character, including but not limited to:
1. Loss of use of productive facilities or equipment.
2. Lost profits, property damage, and/or expenses incurred in reliance on Compression Systems’
performance hereunder.
3. Lost production, whether suffered by the purchaser or any other third party.
Compression Systems disclaims all liability for any and all costs, claims, demands, expenses, or
other damages, either direct or indirect, incident to all property damage arising out of any cause of
action based on strict liability.
Unauthorized Repair
In the event that the owner allows the compressor to be serviced or repaired by unauthorized
personnel, the coverage of the original warranty policy will be automatically terminated.
1—11
CCV 5-Year Warranty

SM
THE EDGE IS RELIABILITY
CONGRATULATIONS!
You have purchased the most reliable turbocompressor avaiable, exclusively from Compression Systems.
Your new compressor is designed to meet your performance requirements with:
Oil-free compressed air
Energy efficiency
High reliability
Easy to install package units
Design flexibility to adapt machines to customer process conditions
Low life cycle costs
CC V is a no up-front-cost extended 5 year air end warranty, for your Turbo Air Cooled 2000 compres-
sor, shipped after October 1, 2004. Simply perform the recommended maintenance outlined in the
Owner’s Manual using Compression Systems authorized service representatives. All maintenance will be
logged every quarter by your service rep. on our easy-to-use online CCV maintenance log tool.
Extended warranty on the compressor, air end only, can be obtained for up to 5 years from the date
of shipment. The parties mutually agree to compliance with the following mandatory requirements:
1. On-line registration at www.c-a-m.com
2. The compressor must incorporate TurboBlend™ or equivalent oil at initial startup.
3. Guidelines for compressor maintenance shall be followed in accordance with Compression Systems
operating manuals.
4. Only genuine Compression Systems parts may be used.
5. Maintenance performed by a Compression Systems authorized service representative in accordance

with maintenance program check-off lists is required.
6. Quarterly oil samples will be submitted to the designated location, or an oil analysis is to be
provided.
7. Compliance with 5-year warranty terms and conditions.
1—12
Specifications
Section Two
Specifications
♦ General Compressor Specifications
♦ Alarm and Trip Specifications
♦ Compressor Lubricant Requirements
2—1
2—2
Specifications
General Compressor Specifications

The following Table provides definition for some of the abbreviations and symbols used in this section
that may not be obvious to all users.
Abbreviations and Symbols

Item Definition Item Definition
“ Inch or inches GPM Gallons (US) per minute
# Pound or pounds LPS Liters per second
HP Horsepower NPT National (US) Pipe Thread (tapered)
KW Kilowatts FF Flat Faced (Flange)
Kg Kilograms RF Raised-Face (Flange)
ANSI American National Standards Institute
Package Weights for Installation

Complete package including main drive motor
Compressor Rating (HP)→ 150 200 250 300 350
Weight (English) 10,000# 10,000# 10,500# 10,500# 11,000#
Weight (Metric) 4500 kg 4500 kg 4700 kg 4700 kg 5000 kg
Connection Sizes, Ratings and Types (per ANSI)

Air Inlet [A] Air Ejector 3/8” NPT
Air Discharge [B] Control Center 4” diameter (Electrical)
Condensate Drain 1/2” NPT Pressure Transducer 1/4” NPT
Notes:
[A] No connection required with standard package-mounted inlet filter assembly.
Optional 8”--150# ANSI FF flange (Enclosure modifications required. See Section Three)
[B] Standard: 3” sch. 40 pipe, grooved for Victaulic connection.
Available options include Victaulic pipe coupling or Victaulic flange (150#) ANSI.
Maintenance Weights
(Approximate Values, lbs/(kg))
Item Weight Item Weight

Bullgear Cover 350 (160) 1st Stage Inlet 200 (90)
Bullgear Assembly 325 (150) 2nd Stage Inlet 110 (50)
Intercooler Bundles 70 (32) 3rd Stage Inlet 75 (35)
Coupling Bolt Torque Values

English Units Metric Units
Geared Coupling 63 ft-lbs. 85 Nm
Dry Coupling Main Drive Coupling Bolts Lubed 110 ft-lbs. 149 Nm
Dry Coupling Connecting Bolts 12 ft-lbs. 16 Nm
2—3
Miscellaneous Bolt Torque Values

Unless noted elsewhere, all bolts must be torqued to the following. All values are based on clean, unlubricated
threads.
Bolt Diameter Torque Range
English Units (ft-lbs) Metric Units (Nm)
5/8” (16 mm) 88 – 98 120 – 132
¾” (19 mm) 143 – 157 195 – 210
7/8” (22 mm) 192 – 212 260 – 285
1” (25 mm) 285 – 315 385 – 425
Lubrication System Operating Conditions

Item English Units ISO Units
Reservoir Capacity 40 gallons (USA) 150 liters
Minimum Reservoir Temperature Prior to Startup 60° F 15° C
Normal System Operating Temperature 120° F 50° C
Normal System Operating Pressure 120 psig 8.2 barg
Air Ejector Operating Pressure Range 25 - 30 psig 1.7 - 2.0 barg
Required Vacuum 8-10” H2O 100-250 mm H2O
Cooling Fan Motor Starter - Electrical Factors

System [A]
Motor Rating Power Full Load Amps Fuse
10 HP (7.5 kW) 460V / 3F / 60 Hz 12.6 25 amps
Notes:
[A] Other voltages are available. Must be specified at the time of order entry.
Discharge Connection Load Limits

Excess loads may cause connection failure.
English Units Metric Units
Maximum Allowable Force 200 lbs. 880 N
Maximum Allowable Moment 100 ft-lbs. 135 Nm
2—4
Specifications
Compressor / Motor Control Center

Mechanical Factors
Dimensions English Units Metric Units
Height x Width x Depth 43” x 50” x 16” 1100 x 1270 x 400 mm
Weight 400 lbs 180 kg
Environmental Factors
Temperature: English Units Metric Units
Operating Range [A] 32° to 140°F O° to 60°C
Storage Limits -4° to 140°F -20° to 60°C
Humidity:
Operating Range 0 to 95% Relative Humidity (non-condensing)
Storage Range 0 to 100% Relative Humidity (non-condensing)
Location Classification (per USA standards):
Standard: Indoor NEMA 12 (water and dust resistant)
Optional: Outdoor NEMA 4 (watertight and dustproof)
Optional: Corrosive Outdoor NEMA 4X (achieved with coating material)
Optional: Hazardous Not Available
Notes:
[A] Panel heaters and coolers are available options.
Safety Approvals (Extra Cost Options)
UL (USA) CSA (Canada) CE (Europe)
Main Drive Motor Controller / Starter

Electrical Factors
Full Voltage Current Transformer Amperage [A]
Motor Rating (HP) 150 175 200 250 300 350
380 V / 50 Hz 300 300 400 400 500 600
380 V / 60 Hz 300 300 400 400 500 600
400 V / 50 Hz 300 300 300 400 500 600
415 V / 50 Hz 300 300 300 400 500 600
440 V / 60 Hz 300 300 300 400 500 500
460 V / 60 Hz 200 300 300 400 400 500
575 V / 60 Hz 200 200 300 300 400 400
[B] —- —- —- 100 100 100
Notes:
[A] Full voltage starting values. Refer to contract documents for Wye-Delta Starting information.
[B] All medium voltage applications: 2300 V, 3000 V, 3300 V, 4160 V, and 6600 V.
Control Circuit Requirements
24 VDC 10 amps 220 VAC 6 amps
120 VAC 10 amps 230 / 240 VAC 6 amps
2—5
Maestro Control System

Electrical Factors
The power supply voltages are factory configured and must be specified at the time of order entry.
Property Value
Rated Voltage 100 – 240 VAC
Input Voltage Range 90-264 VAC
Rated Frequency Range 50 – 60 Hz
Input Frequency Range 47 – 63 Hz
Power Consumption 750 VA
Oil Pump Motor Starter

Electrical Factors
System [A]
Motor Rating Power FLA Fuse
3.0 HP (2.25 Kw) (optional) 460 V/ 3Φ/ 60 Hz 4.8 amps 8.0 amps
Notes:
[A] Other voltages are available. Must be specified at the time of order entry.
Oil Heater (Optional) ***

Electrical Factors
Power Rating Current Draw Power Rating Current Draw
380 Volts 250 Watts 0.66 amp 460 Volts 370 Watts 0.80 amp
415 Volts 300 Watts 0.72 amp 575 Volts 575 Watts 1.00 amp
***Voltages must be specified at time of order entry.
2—6
Specifications
Alarm and Trip Specifications

The tables below show the Alarm and Trip values of the key parameters for the Turbo Air 2000 com-
pressor.
If an Alarm value is reached, the compressor will continue to run but the control system will show the
item that generated the alarm.
If a Trip value is reached, the control system will shut down the compressor.
ALARM and TRIP Setpoints (English Units)

ALARM TRIP
Condition Low High Low High
Standard:
Compressor Stage Vibration (mils) - 1.5 - 2.0
Oil Pressure (psi) 100 180 80 200
Oil Temperature (ºF) 70 135 60 145
Stage Inlet Air Temperature (ºF) - 130 - 140
Optional:
Inlet Air Filter Pressure Drop (inches of water) - 10 - -
Oil Filter Pressure Drop (psi) - 15 - 20
ALARM and TRIP Setpoints (Metric Units)

ALARM TRIP
Condition Low High Low High
Standard:
Compressor Stage Vibration (µm) - 38 - 50
Oil Pressure (bar) 6.9 12.4 5.5 13.79
Oil Temperature (ºC) 21 57 16 63
Stage Inlet Air Temperature (ºC) - 55 - 60
Optional:
Inlet Air Filter Pressure Drop (mm of water) - 250 - -
Oil Filter Pressure Drop (bar) - 1.0 - 1.4
2—7
Compressor Lubricant Requirements

The user must obtain the following required lubricants for use with the Turbo Air 2000 Compressor:
• Acceptable compressor oil

• Acceptable motor bearing grease
• Acceptable coupling grease
Complete information about these lubricants is included in this section. Specific instructions for proce-
dures involving their use are included in Section Five, Maintenance.
It is the user’s responsibility to provide all lubricants (including compressor oil, motor grease, and
coupling grease) at the initial startup and during subsequent operation. It is very important for all
compressor users to follow specific guidelines regarding lubricant selection and proper use in order
to assure optimal performance of the Turbo Air 2000 Compressor.
Compressor Oil Selection

The correct lubricating oil is critical to satisfactory overall compressor performance. When operating
the Turbo Air 2000 Compressor, use only high-quality, rust- and oxidation-inhibiting oil that resists
foaming and that does not break down under severe operating pressures and temperatures. Incorrect
or poor quality lubricating oil can adversely effect high-speed shaft dynamics and seriously damage
critical compressor components.
While there are many quality oil products on the market today, not all have been demonstrated to
function optimally in situations involving high-speed rotordynamics. For this reason, Compression
Systems has formulated a lubricant that is as advanced as today’s high-tech compressors. TurboBlendTM
lubricating oil is an exceptional lubricant formulated using a hydrocracked base stock and performance
enhancing additives.
Hydrocracking is an advanced oil processing technology that is far superior to solvent refining. It
converts crude oils into base stocks of unparalleled purity. So pure, in fact, and so highly refined that
this new class of lubricant is free of the contaminants that cause lubricant breakdown ensuring longer-
lasting compressor performance. The only additives in TurboBlend Lubricating Oil are those selected
exclusively by Compression Systems scientists and engineers to increase performance. In test after test
of standard quality indicators, TurboBlend lubricating oil outperforms solvent refined, commercially
available oils.
TurboBlend lubricating oil is available through your authorized Compression Systems representative or
directly from the Compression Systems Parts Department. Refer to Section Seven of this manual for
part numbering and ordering information.
Standards
Excellent operating performance will be achieved when using TurboBlend lubricating oil. However, if
the compressor owner or user chooses to pursue a near equivalent substitute, the subject oil must
conform to the following characteristics:
2—8
Specifications
• Refined from high-quality mineral oil stock.

• Free from any contaminants or impurities that may be abrasive or have a lapping action.
• Contain additives to provide:
- a high level of oxidation stability,
- a high degree of wear protection,
- rapid separation from entrained gases,
- foam-free operation,
- rust-free and corrosion-free operation, and
- resistance to the formation of sludge and harmful resin-like deposits.
• Capable of maintaining high flow strength and not break down under extremes of pressure and
temperature.
Animal, vegetable and mineral oils of poor quality must be avoided as these oils would tend to oxidize,
develop acids, and form sludge or resin-like deposits on rotating elements. Such deposits may be of
sufficient volume to cause very high, localized loadings that will lead to a premature breakdown of the
load-carrying capacity of the oil. This will result in worn gears and scored bearings.
Specifications
TurboBlend lubricating oil meets or exceeds the performance standards listed in Table 2—1. Any
substitute or equivalent oil selected for use in the Turbo Air 2000 Compressor by the compressor owner
must exhibit similar results.
Property Test Method Performance

Viscosity:
at 40°C ASTM D445 46 Cst
at 100°C ASTM D445 7 Cst
Viscosity Index: ASTM D2270 >100
Four Ball Wear Test:
(40 Kg, 1200 RPM, 75°C, 1 Hour) ASTM D4172 ≤ 0.4 mm
Water Separability:
(54°C and 82°C) ASTM D1401 <3 ml at 15 minutes
Foaming Characteristic - Sequences I, II & III:
Tendency/Stability ASTM D892 <10 ml / 0
Gas Bubble Retention Time:
at 50°C ASTM D3427 ≤ 5 minutes
Rust Test:
Distilled Water ASTM D665A Pass
Synthetic Sea Water ASTM D665B Pass
Rotating Bomb Oxidation Test: ASTM D2272 > 400 minutes
Base Oil is to be refined from high-grade mineral oil stock.
Table 2—1 Compression Systems Oil Specification
2—9
Other Oil Selection Considerations

Incorrect or poor quality lubricating oil can seriously damage the compressor’s rotating and mechanical
elements. Do not merely rely on an oil dealer recommendation when selecting turbine oil, and do not
compromise quality in an attempt to economize. Many reputable brand name oil products exist, but
not all perform effectively in the demanding world of high-speed turbomachinery.
Do not mix different brands of oil. This is inadvisable because some oils are incompatible, and a wrong
combination of additives could cause serious machine damage and/or poor overall performance. The
lubrication requirements of the Turbo Air 2000 Compressor are not so severe as to require the qualities
of high-cost synthetic oil. In addition, Compression Systems products are not designed to use synthetic
oils. Therefore, use of such products is not recommended and is done at the owner’s risk.
CAUTION:
To ensure optimum performance and to avoid possible compressor damage, always be
certain to follow the guidelines listed below.
• Use only Compression Systems TurboBlend lubricating oil or a high-quality turbine oil
that meets the specifications in Table 2—1.
• Do not mix different oils.
• Avoid the use of synthetic oils.
• Remember that use of unspecified oil is done at the owner’s risk.
Inspection and Testing

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

Compare an oil sample from the reservoir with new oil. Any color change suggests some type of
deterioration. Darkness implies contamination from acid buildup while muddiness is an indication
of water.
• Viscosity, Acid and Particle Count
Tests for these properties required qualitative analyses by a reputable laboratory. Follow the
recommendations of the laboratory with regard to oil replacement.
Compression Systems offers an oil analysis service. Sampling kits and information about this service are
available through an authorized Sales and Service Representative, or directly through the Compression
Systems Aftermarket Department. (See Table 7-1 of this manual for sampling kit part number informa-
tion.)
2—10
Specifications
Other Required Lubricants

The user must also provide an array of other lubricant products as specified.
Motor Bearing Lubricants

The user must provide lubricants for the main drive motor and the oil pump and fan motor. To ensure
long life of the bearings, it is necessary to maintain both proper alignment and proper lubrication
levels at all times. The large, squirrel cage inductor motor of the Turbo Air 2000 Compressor employs
anti-friction bearings.
Refer to the motor manufacturer’s instructions provided separately for complete information
regarding correct oil bearing lubrication maintenance procedures.
For best results with anti-friction bearings, only use grease recommended by the motor manufacturer.
Drive Coupling Grease

The user must provide coupling grease at the time of installation and during compressor operation.
This coupling grease must meet very specific requirements. Conventional factory greases do not provide
complete lubrication for high-speed flexible couplings. The lithium soaps used as thickeners separate,
forcing the soaps into places that require lubrication. The soaps then act as abrasives that accelerate
wear.
Compression Systems endorses only greases with a K 36 Test Rating of 0/24. These are the only greases
found acceptable by the American Gear Manufacturer’s Association (AGMA) because of their high
resistance to centrifugal separation. (Compression Systems Coupling Grease is specially formulated to
meet this very specific requirement. Refer to Table 7—1 for part number information.)
CAUTION:
Do not use a coupling grease with a K36 Test Rating above 0/24. Since other products may
cause premature wear and/or other damage, always use Compression Systems Coupling
Grease only.
2—11
2—12
Installation
Section Three
Installation
♦ General Considerations
♦ The Installation Work Schedule
♦ Site Considerations
♦ Process Air Piping
♦ Discharge Air Piping
♦ Utility Piping
♦ Electrical Interface
♦ Receiving, Lifting, and More...
♦ The Installaton Inspection
♦ Preparing for Startup
♦ Initial Compressor Startup
3—1
3—2
Installation
General Considerations
Advance planning and preparation will help to simplify and expedite the compressor installation
process. This Installation Section gives an overview of the entire process, from preliminary site prepara-
tion to the final preparations before the initial startup.
The Installation Work Schedule lists the various considerations that the owner must address before and
during the installation process, up to and including the initial startup procedure.
During the Initial Startup Service Inspection, the Compression Systems trained and authorized service
representative checks the completed installation work including all peripheral piping and electrical
work. The service representative also checks the lubrication system, adjusts the control system (if
necessary), verifies motor alignment, starts the compressor and instructs operating personnel.
3—3
The Installation Work Schedule

Before beginning the actual compressor installation process, the installer should review this Installation
Work Schedule for an overview of the various considerations and procedures involved. Each aspect of
the installation listed in this schedule is fully described in subsequent text and/or Section Two, Compres-
sor Specifications.
Before delivery, review all technical documents provided, including the Installation Manual and all
relevant specifications and drawings supplied separately.
1. Select a well-suited location in accordance with the minimum recommended space requirements for
the compressor and future maintenance.
2. Review the list of parts, supplies, tools, and labor that the owner must supply at installation, and
arrange for them all to be readily available on site.
3. Be sure that all required preparations and provisions have been made with regard to the founda-
tion, piping, and electrical connections, or (if necessary) arrange for suitable storage for the
compressor until the time of installation.
4. At least three weeks before the projected initial startup date, contact your local Compression
Systems representative to schedule startup assistance.
5. Upon its arrival, inspect the compressor and check loose-shipped equipment against the packing
list; if any damage or shortage is noted, immediately report it to the carrier.
6. Set the compressor on the foundation or (if required) put it into storage until the installation may
be completed.
7. After it is in place, secure the compressor on the foundation bolts.
8. Install the external air piping in accordance with the information in this section and the contract
drawings. *
9. Fabricate the condensate drain pipes and control devices in accordance with the instructions in this
section. *
10. Properly connect the instrument air line to the reservoir vent ejector system.
11. Make all electrical connections.
12. Check the site a final time for conformance to all applicable codes, all relevant recommendations,
and for overall cleanliness and tidiness.
* Certain packaging options involving various piping configurations are available through
Compression Systems. When included from the factory, considerable savings can be
realized at installation. Details of these options are included later in this manual.
3—4
Installation
Labor, Supplies, Equipment, and Tools

It is the owner’s responsibility to prepare the site and to provide any necessary labor, supplies, tools, or
additional equipment required for installation beyond what is included in the purchase package.
The following lists include the supplies necessary for site preparation and installation and the tools
necessary for installation and future maintenance. Since the Turbo Air 2000 Compressor is designed for
easy installation, most of the tools or supplies required should be already on hand or easily available.
Materials Required for Compressor Installation

Supplies
Foundation bolts
Shims (for leveling)
All external piping supplies
All external wiring and electrical conduits
Compressor oil (See Specifications)
Coupling grease (See Specifications)
Motor bearing grease (See Specifications)
Equipment *
Main drive motor controller (if not included as part of the compressor package)
Oil pump motor starter and oil heater contactor (if not included as part of the compressor package)
Inlet startup screen (if required)
Expansion joints (for inlet and discharge piping)
Condensate traps, or valves
Air system block valve
Air dryer (if necessary)
Tools
“Port-a-Power” or hydraulic jack
Allen wrenches and Drive sockets with extensions
Digital multimeter
Pipe wrenches, Adjustable wrenches, and Vise grips
Torque wrench (to 200 ft-lbs. or 300 NM)
Screwdrivers
Open end and box wrenches
*Some equipment may have been purchased with the compressor. Check engineering documents provided
separately for definition of Compression Systems’ scope-of-supply.
Table 3—1. Materials Required for Compressor Installation
3—5
Site Considerations
Select the installation site and make any required preparations before compressor delivery. This will
allow for a quick startup shortly after the equipment arrives. When selecting and preparing the
installation site, also keep in mind that equipment located in a well planned, easily accessible area
generally gets better attention from operating and maintenance personnel.
The standard Turbo Air 2000 Compressor is designed for indoor installation. For outdoor installation, it
is necessary to purchase the optional TEFC motor and NEMA-4 electrical option as part of the package.
Environment
Included as part of the standard scope-of-supply of the TAC-2000 Compressor is an inlet air filter
already pre-packaged inside of the noise enclosure. Therefore, when selecting a location for the
machine, take into consideration the quality of the air that the unit will be ingesting. However, if the
buyer opts to select the remote inlet air filter option, the buyer will be required to provide additional
inlet air piping and modifications to the noise enclosure.
A clean environment is important for optimal performance. Locate the compressor inlet air filter away
from chimneys, cooling towers, steam exhausts, or any other possible sources of air contamination
with foreign matter. If the filter is NOT being mounted on the compressor package, keep the fitler
mounted in a level position at least 6 ft. (2 m) from any window, wall, or roof to further isolate it from
any airborne contaminants.
When selecting an outdoor installation site, consider prevailing and local ground wind patterns as well
as the immediate atmospheric conditions surrounding the unit. Such factors may have long-term
effects on overall compressor operation.
CAUTION:
Select the compressor site carefully with regard to possible contamination with foreign
matter. Dust, corrosive vapors, or other airborne foreign matter will adversely affect
compressor performance and motor insulation life.
Envelope
Provide an adequate envelope (space allowance) around the unit. Figure 3—1 illustrates the recom-
mended minimum envelope in keeping with the compressor’s overall dimensions. Allow an additional 3
ft. (1 m) around the sides and back of the compressor to provide adequate clearance for installation,
inspection, and future maintenance.
Ventilation
The exhaust or discharge flow from the heat exchangers can range from 15,000 to 20,000 cubic feet
per minute (cfm) (33,000 cubic meters per hour), and may contain as much as 1,000,000 BTU’s per hour.
Therefore, the compressor should not be installed in a confined area where the discharge air would be
allowed to recirculate back through the inlet ports located on the lower sections of the enclosure
doors.
WARNING:
Do not locate the compressor in a confined area where the discharge air from the heat
exchangers would be allowed to recirculate. The air temperature in such a confided area
will increase rapidly and have a detrimental effect on the heat exchangers performance,
even creating an operating alarm or trip condition.
The exhaust flow of the heat exchangers must be adequately vented without creating backpressure on
the cooling system fan. A maximum backpressure of 1.0 inches (2.5 cm) of water column (WC) is
allowed. Any ductwork added must be removable for maintenance.
3—6
Installation
Heat Recovery
The warm exhaust flow may be used for heating provided that it is properly filtered and ductwork fans
are used to move the air. Take notice of the backpressure limit stated above.
Acoustics
The mechanical processes of compressor operation will affect sound levels in the area immediately
around the compressor. If the installation site is an area where hard walls and low, hard ceilings will
reflect and amplify noise, it is advisable to cover the reflective surfaces with acoustical insulation.
Cooler Protection
Adequate protection is recommended to prevent debris from collecting on top of the heat exchangers.
An accumulation of trash on the coolers will hamper the performance of the heat exchangers.
Condensate Drains
Water in the form of condensate will separate from the air after passing through each heat exchanger.
Adequate open drains must be provided to carry away the condensate. Do not manifold drains
together as condensate from higher pressure heat exchangers will be forced into lower pressure
coolers.
Condensate from the Turbo Air Cooled 2000 Compressor is completely oil-free and is environmentally
safe.
(Refer to the Utility Piping subsection for additional information and requirements for condensate
drain piping,)
Foundation
The Turbo Air 2000 Compressor can be installed directly onto the factory floor so long as the floor
meets the following minimum requirements:
• It must be constructed of good quality, reinforced concrete to provide a rigid and substantial
base.
• It must be one continuous integral slab with a minimum thickness of 4-6 in. (100-150 mm).
90.00”
(2286)
134.75 75.67”
(3423) (1922)
Figure 3—1. Compressor Envelope
3—7
Process Air Piping

Process air piping for a typical air compressor installation includes three subsystems: the inlet air piping,
the discharge air piping, and the bypass piping arrangements. One of the inherent features of a
Turbo Air 2000 Compressor is that it was designed for ease of installation. The bypass piping, with
silencer, is already integral to the package.
When designing and fabricating the compressor air piping, keep in mind that these piping systems are
the “lifelines” of any compressor installation. Improperly designed piping systems may cause later
problems. The most common reason for compressor control problems is failure to follow the
discharge piping installation guidelines and/or the requirements listed on the contract-specific
drawings supplied separately. If requirements and specifications are not met, the improperly designed
piping system will cause delays and may require costly and time-consuming modifications.
To ensure a successful process air piping installation, always:
• Use clean pipes to be sure that no foreign material enters the compressor.
• Keep the piping as short and direct as possible.
• Clean the piping thoroughly after fabrication.
• Use a discharge block valve as indicated.
• Support the piping properly so that the supports (rather than the compressor) carry the load.
• Provide drains at low points to carry away any collected condensate.
DANGER:
Remember that it is the owner’s and installer’s responsibility to provide appropriate
service piping to and from the compressor. Failure to follow the requirements and recom-
mendations listed will cause mechanical failure, property damage, serious injury, and/or
death.
3—8
Installation
Inlet Air Piping

Inlet air piping is not required for the standard compressor package. An air filter has been pre- pack-
aged inside of the noise enclosure. However, if the buyer opts for the remotely mounted inlet air filter
option, follow the recommendations below. (Note that modifications will also be required to the noise
enclosure when the remote inlet air filter option is applied.)
The optional inlet air filter may be bolted directly to the compressor’s inlet flange. The compressor’s
piping supports are of sufficient strength to support this filter.
Figure 3—3 schematically shows a typical air piping arrangement relocating the inlet air filter away from
the compressor package. It includes various standard and optional components.
A. Inlet Filter Silencer (option)

B. Expansion Joint (option)
C. Startup Screen (option)
D. Inlet Flange
B E. Pipe Reducer
C F. Throttle Valve
D G. Valve Actuator
G H. First Compression Stage
E
F
Roof Line
Figure 3—3. Inlet Air Piping
When designing and installing the inlet air piping, it is important to carefully consider the follow-
ing information and recommendations.
The inlet connection to the Turbo Air 2000 Compressor is a cast iron reducer with a standard ANSI
B36.10 (American National Standards Institute) 8-inch flat-faced flange.
3—9
Piping Material
When selecting the pipe to be used, it is advisable to either select corrosion-resistant piping or, alterna-
tively, to treat the pipe to provide additional corrosion protection. When fabricating the inlet air
piping, also take care to provide suitable support so as to sufficiently isolate the piping forces from the
compressor itself.
In those instances when fiberglass piping will be used for the inlet air lines, be sure to follow these
recommendations:
• Select pipe material that can tolerate bypass air temperatures of up to 350°F (175°C).
• Use pipe and fittings that are filament wound with continuous glass filaments and epoxy resin.
• Provide the fiberglass piping with additional reinforcement to evenly distribute the load along
the pipe.
• Insulate the pipe to minimize noise.
Drains
Provide adequate drains at low points to accommodate the condensate that collects on the inlet line
during compressor shutdown periods. This will deter rusting and eventual erosion of aerodynamic
components, either of which would otherwise reduce overall compressor performance and component
life span.
3—10
Installation
Discharge Air Piping

The discharge air piping system shown schematically in Figure 3—6 represents the factory-standard for
packaging of control components, as well as, the minimum requirements for piping, pressure sensing
locations and safety components. The compressor vent (or bypass) piping which includes the bypass
valve and silencer are already pre-mounted and wired on the Turbo Air 2000 Compressor package. Only
a minimal amount of the field piping design and installation is left to the owner/installer.
A. Aftercooler 1. Air flow from last stage of compressor.

B. Victaulic Pipe Coupling 2. Air flow to user’s compressed air system.
C. Bypass Valve (packaged) 3. Bypass air flow returned to compressor inlet.
D. Blowoff Silencer (packaged) 4. Pressure signal to Air System Pressure transmitter.
E. Flanged Discharge Air Connection 5. Pressure signal to Compressor Discharge Pressure
F. Expansion Joint [A] transmitter.
G. Check Valve (by Cooper)
H. Block Valve [A]
Compression Sytems Owner/User

Scope-of-Supply Scope-of-Supply
Notes:
[A] Required pipeline component available as an extra cost option.
Figure 3—6. Discharge Air Piping Requirements - Standard Packaging
When designing and installing the discharge air system, the following information and recommenda-
tions should be taken into consideration.
Connection
The compressor discharge air connection is a standard victaulic grooved pipe. When attaching the
discharge pipe, refer to the contract-specific Installation Arrangement drawing supplied separately for
specific size loading information.
3—11
Piping Material
While corrosion on the discharge air side does not present the same problem as it does on the intake
air piping, it is still a concern. Rust can damage delicate instrumentation, pneumatic tools, or processes
that require non-contaminated air.
The principal consideration in the selection of piping materials should be safety. The United States,
Canada, and most other countries strictly prohibit the use of unprotected polyvinyl chloride (PVC)
piping to transport compressed air or other compressed gases. Compression Systems also advises
against using soldered copper fittings and rubber hoses in discharge air piping. If fabricating the air
piping with flexible joints and flexlines, be sure that they meet the operating parameters of the system.
Compression Systems recommends that all pressure-holding pipe be in accordance with the standards
established by the American National Standards Institute (ANSI) as well as the American Society of
Mechanical Engineers’ (ASME) Standard B31.8-1986.
WARNING:
Be certain to follow all specified requirements and guidelines. Failure to correctly follow
the above or other specified discharge air piping design guidelines will cause compressor
malfunction and/or damage.
Drains
The high pressure air leaving the compressor contains some moisture. Therefore, it is necessary to
provide drains at all low points to remove any condensate that may collect along the discharge system.
Fabrication
The high pressures, long piping runs, and heavy accessories in the discharge air line makes design
considerations necessarily more detailed than with the intake air lines.
WARNING:
Do not exceed the 100 lb. (445 N) Maximum Allowable Force or the Maximum Allowable
moment of 50 ft-lbs. (67.8 Nm) on the compressor discharge connection. Excess weight
may cause pipe connection failure.
Depending on the control method utilized, the pressure-sensing lines should be located either before
and/or after the check valve. Refer to the Flow Schematic and Installation Arrangement drawings
supplied separately for specific placement.
3—12
Installation
Discharge Expansion Joint

Compression Systems recommends the use of the Discharge Expansion Joint option to ensure a safe
discharge piping system design. The discharge expansion joint must be mounted vertically, directly at
the discharge flange of the compressor. Because braided type expansion joints cannot withstand a
collapsing force, it is necessary to install such joints with sufficient pre-tension to counteract such
forces. If a “tied” expansion joint is utilized, it is necessary to take special care to be certain that the
axial and lateral flexibilities of the joint are not unduly restricted.
WARNING:
Be certain that the discharge expansion joint is installed correctly. With improper installa-
tion, the release of higher-pressure energy in the discharge air poses the threat of serious
injury to operating personnel.
Mounted Discharge Check Valve

A discharge check valve must be included in the discharge piping arrangement to prevent the reverse
flow of air through the compressor during unloaded operation. Compression Systems supplies a check
valve that was selected for its high reliability and exceptional quality. The relatively large air passage
area provides low pressure drop and fast closing features important to the operation and security of
the compressor.
The standard Turbo Air 2000 Compressor package includes an installed check valve. The piping provides
the recommended minimum of four pipe diameters required for proper valve operation. After installa-
tion, proper discharge check valve operation should be routinely verified as part of the compressor
maintenance program.
WARNING:
Before operating the compressor, be certain that the discharge check valve is correctly
positioned with the disc-end closest to the compressor flange. Improper installation of the
check valve may cause compressor damage and/or personal injury.
3—13
Block Valve
All compressor installations must include a block valve to insulate the compressor from the remainder of
the pressure system in case of a check valve failure. The user must supply the block valve, which must
be installed after the check valve.
WARNING:
Whenever the compressor is being serviced, be certain to close and lock the block valve.
These measures are necessary to protect the compressor whenever the check valve is being
serviced or otherwise not functional.
Automatic Block Valve Option

The Automatic Block Valve option fits between two 150-lb. ANSI raised-face flanges in the discharge air
piping. The recommended installation is after the aftercooler (if so equipped) and at least four pipe
lengths beyond the discharge check valve. While the valve orientation is at the installer’s discretion,
accessibility should be considered if the Automatic Block Valve is to be used as a lockout device during
compressor service.
The valve actuator requires a 80-psig air supply for a three-stage compressor or a 40-psig air supply for
a two-stage compressor. If available, use the instrument air supply; alternatively, tap the pipe located
immediately upstream of the valve itself. The supply air should be connected to the lockout valve on
the block valve assembly. Verify correct operation of the Automatic Block Valve at the initial startup,
since valve malfunction may cause compressor surging. Refer to Compression Systems AAEDR-A-008,
Automatic Block Valve, for additional information on the Automatic Block Valve option.
Sound Suppression
Inlet and discharge air piping are major sound emitters in any compressor installation. For greater
sound suppression, insulate local surfaces with sound absorbing materials. For maximum sound suppres-
sion, it is necessary to insulate the entire air path as follows:
• All inlet air piping from the opening in the compressor room (if housed indoors) to the inlet
flange.
• All discharge air components, including piping and fittings.
• All blow-off valve piping, including the blow-off valve and silencer.
Additional information about the insulation of piping for noise control is contained in Compression
Systems Engineering Specification AAIL-950, Insulation for Noise Control, available upon request.
3—14
Installation
Utility Piping
The utility piping is defined as any piping, tubing or electrical conduit external to the compressor
package, which support subsystems required to complete the compressor installation. Included in this
category are:
• The condensate drain piping.
• The instrument air piping for the reservoir vent ejector system.
• The instrument tubing which connects various pressure-sensing points to transducers located on
the compressor package.
• Any medium- and/or high-voltage electrical conduit for the main drive motor, Maestro Control
Panel, oil pump motor and optional lubricating oil heater.
The user/installer is responsible for providing all external piping, tubing and conduit, as well as for the
basic design of the utility piping. Typical arrangements for some of the utility piping are included in
this section.
Important time-saving elements of the Turbo Air 2000 Compressor are the many standard and
optional packaging features designed to minimize the work of the installer. Be sure to understand
the scope-of-supply illustrated on the process diagrams supplied separately before planning the
installation work to be required.
To ensure successful utility piping installations, always:

• Use clean piping to be sure no foreign material enters the compressor’s subsystems’ components.
• Keep the piping, tubing or conduit as short and direct as possible.
• Clean the piping and conduit thoroughly after fabrication.
• Support the piping and conduit properly, where necessary, so that the support (rather than the
compressor) carry the load.
• Provide drop legs or drains at low points to carry away any collected condensate.
WARNING:
Remember that it is the owner’s and installer’s responsibility to provide appropriate utility
piping to and from the compressor. Failure to follow good industrial practices and the
requirements and recommendations listed could cause poor compressor performance,
mechanical failure, property damage, and/or personal injury.
3—15
Condensate Drain Piping

During air compressor operation, condensate collects in each intercooler chamber as the air is cooled.
(This is not the case when the compressor is used in dry nitrogen service.) In order to prevent the
condensate from being carried over and entering the next stage of compression, the condensate in
each of the intercooler chambers must be drained into an open drain or trough. The open drain
allows not only visual verification of condensate removal, but it also assures that the condensate will
not be drawn back into the compressor when the compressor is unloaded.
CAUTION:
Do not manifold the three drain assemblies. This is the single most common error made at
the time of compressor installation. Each must discharge individually into an open drain
or trough to prevent condensate from higher-pressure chambers being forced back into
lower pressure chambers.
A variety of control devices can be used in the condensate removal piping system, including:
• Standard gate valves, operated by hand.
• Float traps which are self-actuating.
• Solenoid valves, operated by the Maestro Control System.
Three ½” NPT connections (one for each cooler) are located on the separators. The condensate piping
and control devices attach to these connections. Figure 3—10 illustrate a typical condensate drain
piping arrangement. It is also necessary to include a manual bypass valves and piping with whichever
type of drain control device is utilized.
It is also advisable to keep the condensate draining system open during shutdown to prevent conden-
sate accumulation in the compressor.
Figure 3—10. Typical Condensate Removal Piping Arrangement
3—16
Installation
Solenoid Condensate Drain Piping Option

The solenoid-operated drain valves are wired to the control system, which opens and closes the drain
valves at user set intervals. When the valve opens air pressure within the cooler chamber expels the
condensate to the open drain. See Figure 3—13 below.
Pneumatic Condensate Drain Option

The LiquidatorTM Pneumatic Condensate Draining System option is a demand-operated trap that
automatically drains condensate without any loss of compressed air. Energy savings can be realized
using this system over other, time-based, draining systems. See Compression Systems Engineering Data
Release, AAEDR-D-005, for additional information. See Figure 3—14 below.
CAUTION:
The owner is responsible for properly maintaining the intercooler and aftercooler conden-
sate removal system. Failure to provide regular maintenance can damage intercooler
components and the compressors air handling parts.
D
D
D
B
A D
A
C C
C
C
A. Solenoid Drain Valve
B. Liquidator drain trap
C. Manual Bypass Valve
D. Manual Block Valve
Figure 3—13. Condensate Drain Piping Assembly Figure 3—14. Liquidator TM Pneumatic
Condensate Drain Trap
3—17
Oil Reservoir Vent Ejector Piping

The gearbox and oil reservoir must be vented in a way that will prevent migration of oil and/or oil mist
to the surrounding area or other parts of the compressor. The Turbo Air 2000 Compressor utilizes a
simple ejector (or venturi-tube) powered by clean, dry, filtered air. This ejector creates a slight vacuum
inside the gearbox and oil reservoir to prevent the unwanted migration of oil and oil mist.
WARNING:
Introducing water into the oil reservoir will have adverse effects on the lubricating oil and
can cause severe damage to the compressor. Be sure the ejector’s supply air comes from a
clean and dry source.
The ejector and filter assembly is located at the top of the oil reservoir. The relevant engineering
drawings (supplied separately) define the precise connection point and define the specific air require-
ments. If the air supply pressure varies, it is recommended that a pressure regulator with gauge be
installed for control of pressure to the ejector. The regulator should be installed in the air supply line
just before the ejector itself.
Since it is the routing and distance of the piping at any particular installation are the principal deter-
mining factors, it is the installer’s responsibility to correctly size the air supply piping. (Section Four, The
Lubrication System, includes additional important information about the operation of the ejector/filter
system.)
Instrument Tubing
To ensure a successful instrument tubing installation, always:
• Use steel tubing in order to avoid kinks or other common problems, which are inherent with
copper tubing. (Stainless steel is preferred to be sure that no foreign matter, like rust or scale,
can enter the pressure instruments.)
• Keep the tubing runs as short and direct as possible.
• Do not include block or shut-off valves that can interrupt the pressure signal.
• Provide drop legs at low points with drains to carry away any collected condensate.
• Check for leaks at the connection points in order to avoid faulty pressure readings.
Carefully study the engineering drawing provided in order to understand the purchased scope-of-
supply. It may not be necessary for the user to install any instrument tubing as this work may have
already been completed at the manufacturing facility.
3—18
Installation
Electrical Interface
The standard Turbo Air 2000 Compressor is equipped with a package-mounted control center that
includes the main motor controller ( starter), the oil pump motor starter, the oil heater disconnect
(optional), cooling fan starter, and the Maestro Control System components. All of these package-
mounted electrical devices are pre-wired to terminals in the control center. The user/installer is only
required to install the main power feed, the proper circuit protection and an appropriate earth
ground. Different configurations exist for the various options available. Additional interconnections by
the installer may be required for optional accessories such as automatic condensate removal valves,
automatic block valve, etc. Refer to electrical schematics, provided under separate cover, for more
complete details.
WARNING:
Do not energize or start up the compressor until a Compression Systems service represen-
tative has given full approval. Failure to follow this requirement will compromise any
applicable warranties.
General Wiring
In addition to the basic wiring design, the user must also provide the wire, conduit, protection equip-
ment, etc. When designing and installing the electrical interface, it is necessary to meet the following
minimum requirements:
• Be certain that the main power supply meets specifications, including voltage, frequency, and
(most importantly) the current-carrying capacity of the wires.
• Provide an appropriate separate compressor earth ground that meets local and national code.
(In the United States, refer to Section 250-26 of the National Electrical Code for earth ground
definition.)
• Include proper disconnects such as switches or circuit breakers (either fusible or non-fusible) to
provide complete isolation from the electrical supply.
• If the main power switch that controls the compressor is remotely located or if it is difficult to
lock out the main switch, install a local switch to enable maintenance personnel to isolate the
unit.
• Install and use a lockout system whenever performing maintenance procedures on this or
any other such type of machinery.
If the user requires accessories such as the Solenoid Valve Condensate Removal option, it will be neces-
sary to supply additional interconnections. Refer to the specifications provided separately, or contact a
Compression Systems representative for specific requirements.
DANGER:
Be certain that all electrical work is performed by qualified personnel according to product
specifications and all applicable local or national codes. Failure to heed this requirement
may cause equipment damage, and/or personal injury or death.
3—19
Electrical Conduit
The typical Turbo Air 2000 Compressor installation will require that 3 phase power, and possibly medium
voltage electrical power is delivered to complete the compressor installation. The standard package-
mounted components requiring electrical power are the main drive motor, the main driver motor
controller (starter), the oil pump motor and the Maestro Control Panel (located inside the Control
Center enclosure). Other optional equipment, such as the oil heater, will also require electrical power.
When the main power supply is 600 volts or less, all of these components are pre-wired at the factory
as part of the installation package.
The user/installer is responsible for providing and designing the installation of all external electrical
conduit runs. To ensure successful electrical conduit installation always:
• Use clean, non-corrosive conduit and fittings with no burrs or sharp edges.
• Keep the conduit runs as short and direct as possible.
• Support the conduit properly so as to not impart any unnecessary loads on the components to
which it is being connected.
• Provide drop legs at low points with drains to remove any collected condensate.
WARNING:
Remember that it is the owner’s and installer’s responsibility to apply correct wiring
practices. Failure to follow local electrical codes and good industrial practices could cause
property damage and/or personal injury or death.
3—20
Installation
Main Drive Motor Controls

The major functions of a motor-control system are:
• Starting and stopping of the motor.
• Governing motor output (horsepower/kilowatts), and other monitoring characteristics.
• Protecting personnel and equipment.
There are two standard types of starters offered for squirrel cage induction motors, full voltage starters
and reduced voltage starters. When selecting the motor controls, consider the following information
about these two types. (Of course, selecting the motor starting method is done at the time as order
entry as the choice impacts both the motor controller and the motor.)
Full Voltage Starters

These apply full-line voltage directly to the motor terminals. The Turbo Air 2000 Compressor Control
Center motor controller uses a magnetic starter that contains a mechanism for opening and closing a
set of contacts in the motor circuit and a thermal overload protection device. When the coil is ener-
gized, movable contacts close against stationary contacts, completing the electrical circuit. De-energiz-
ing the coil opens the circuit.
Reduced Voltage Starters

In certain situations, power supply company regulations may limit the current surge or voltage fluctua-
tion that can be imposed on the power supply during motor starting. Several types of motor starters
are designed to apply reduced voltage to the motor windings. When this option is required, the
Turbo 2000 Compressor Control Center motor controller applies a wye-delta (or star-delta) starter
configuration to provide the starting characteristics of minimum line current and smooth acceleration.
In either case, the user should refer to the separate instruction manual and technical drawings pro-
vided by the Control Center manufacturer.
3—21
Receiving, Lifting, and More. . .

The time after the order for a new compressor has been placed and before the actual delivery of the
equipment can be spent planning for the installation. Much of the work described earlier can be
performed or planned for prior to the arrival of the compressor at the installation site.
The Turbo Air 2000 Centrifugal Compressor is shipped as a single assembly. The main drive motor,
lubrication system, and control system are packaged with the compressor on a single skid. However,
since there are many package and accessory options, it is important to refer to the engineering draw-
ings supplied separately for as complete listing of equipment included in Compression Systems’ Scope-
of-Supply.
Receiving
Compression Systems personnel inspect each compressor thoroughly at the factory before shipment.
They then supervise the loading to be sure that no damage occurs and document all loose-shipped
equipment.
It is the responsibility of the purchaser to inspect the compressor for possible damage during transit.
Therefore, plan to inspect the compressor immediately upon delivery. If there appears to be any
damage, report it to the carrier and have the carrier inspect the compressor. After determining the
extent of the damage, have the carrier complete and submit a Concealed Damage Report.
Also, be sure to check all loose-shipped parts and equipment against the packing list. If anything is
missing, report the shortage to the carrier.
Shipments are FOB, Buffalo, NY, USA, and become the property of the purchaser at the risk of the
purchaser.
Lifting/Moving
WARNING:
To avoid personal injury or compressor damage, always follow the proper procedures as
described in this manual. Personnel safety and compressor protection must always be
foremost concerns when lifting or moving the compressor.
WARNING:
The Turbo Air Cooled 2000 Compressor is a rugged piece of industrial equipment, but it
can be damaged as a result of improper handling. Care must be exercised
whenever lifting or moving the unit. Lifting and moving points are clearly identified.
Never use any other areas for lifting or moving.
Slots are provided in the base for use by an industrial forklift. (The typical package could weigh as
much as 11,000 pounds / 5000 kg.) If using a forklift, be sure that the forks extend completely through
the base ( 78 inches / 2.0 m), and take care that the lift is vertical. Use padding where
necessary to prevent scratching or otherwise damaging the enclosure.
3—22
Installation
Figure 3—15. Proper Hoisting Procedure
Lifting eyes are also provided in the base for picking the unit up with an overhead crane. When an
overhead lift is used, properly sized chain spreader bars are required. (See Figure 3—15.)
WARNING:
The noise enclosure framework is not of sufficient strength to allow lifting chains to rest
against it when lifting. The enclosure frame will collapse if proper spreader bars are not
used.
3—23
If a forklift or overhead hoist are not available, the compressor package may be moved on rollers,
dollies or casters. These devices must be of sufficient strength. In order not to incur any damage, do
not move the compressor by pushing against the Control Center enclosure, motor, piping, or other
components. Push or pull the unit only at the designated lift points.
WARNING:
Personnel safety and protection of the compressor are foremost consideration. Use a
forklift or hoist with slings and chains all rated for the weight involved and ensure that
the lifting equipment is in good condition. LIFT THE COMPRESSOR ONLY AT DESIGNATED
LIFT POINTS. All other structural framework is of insufficient strength to support the
entire compressor package.
Storage
The Turbo Air 2000 Compressor has been carefully prepared for a maximum three month indoor
storage period before installation. Lubricant-compatible rust inhibitors protect all operating surfaces.
Storage must be within a heated, indoor area that experiences a minimum of temperature cycling to
prevent damage from condensate forming with the gearbox.
For storage periods longer than three months from the ship date for new equipment, for storage in an
uncontrolled environment, or for existing equipment being shutdown for an extended period, contact
your local authorized Compression Systems representative.
CAUTION:
Failure to provide proper indoor storage or untreated storage periods beyond the three
month duration can void the equipment warranty .
Bolting
If the foundation has been properly prepared, the compressor may be put in place at this time. Com-
pression Systems recommends placing the compressor over foundation bolts, with the nuts tightened
to the recommended torque value. (Refer to Section Two, Compressor Specifications, for specific
information).
Take special care not to rack or twist the base of the compressor when placing it on the foundation. If
necessary, use shims to level the installation package.
3—24
Installation
The Installation Inspection

Before performing the installation inspection, review the Turbo Air 2000 Compressor installation
instructions again. Also, be sure to review any other applicable manufacturer’s instructions for
installation, operation, and maintenance of various other components and equipment including the
main drive motor, the main drive motor controller, the air dryer, etc..
After reviewing the previous items, thoroughly inspect the compressor installation using the
Installation Inspection Checklist in Table 3—2.
Inspection Prior to Initial Startup

As part of the initial startup service, your authorized Compression Systems service representative verifies
that the compressor is ready to be placed in full operation. The service representative should perform
the following inspections and tasks as part of the initial compressor startup service.
1. Check the compressor package for possible transit or handling damage.

2. Verify that the compressor installation is in accordance with the requirements of Compression
Systems.
3. Verify that the inlet and discharge air piping complies with the instructions in this manual and on
the drawings provided with the compressor documentation.
4. Check the condensate drain piping for completeness.
5. Check that all electrical connections have been made correctly.
6. Verify that the compressor oil reservoir is filled with the correct amount TurboBlendTM
Lubricating Oil.
7. Rotate the compressor bullgear and main drive motor shaft (while uncoupled) by hand to verify
that both rotate freely.
8. Verify the correct rotation of the main drive motor, auxiliary oil pump motors and fan motor.
9. Verify that the oil reservoir venting system is receiving the proper, clean, dry air supply.
10. Complete the 2-hour lubrication system flush procedure (Change oil filter element afterwards).
11. Verify the temperature setting of the oil heater option (if included).
12. Make any necessary control system adjustments to satisfy the user’s expected requirements.
13. Oversee the lubrication and reassembly of the main drive coupling.
14. Complete the Installation Inspection Checklist shown in Table 3—2 with customer’s installation
personnel before the initial compressor startup.
3—25
Installation Inspection Checklist

Foundation
Meets the material and thickness requirements
Compressor leveled within specification, foundation bolts properly torqued
Cooling System
Fan motor rotation checked
Cooling air inlets to the enclosure not obstructed
Cooling air inlet filters in place
Top side of heat exchangers clean and free of dirt and other foreign material
Cooling air exhaust properly ducted, if required
Condensate Drain Piping

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

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

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

Correct pipe material and size
Properly supported, without excessive loads
Block valve installed
Check valve installed with recommended pipe volume
Bypass or Modulating Blow-Off Valve installed with recommended discharge pipe volume
Silencer installed (if required)
Clean and free of dirt and other foreign matter
Table 3—2 The Installation Inspection Checklist
3—26
Installation
Installation Inspection Checklist continued…

Oil Reservoir Vent Ejector
Properly connected to the correct amount of clean, dry air
Electrical Interface
Earth ground installed at control panel

All applicable codes met
Motors wired according to manufacturer’s instructions
Motor controllers and starters wired according to manufacturer’s instructions
Control panel wired properly
Shaft Freedom
Motor shaft freely moved when turned by hand
Compressor shaft freely moved when turned by hand
Main Drive Motor

Motor manufacturer’s instruction manual reviewed
Motor bearings properly lubricated
Motor rotation direction checked
Lubrication System
Reservoir filled with correct type and quantity of oil
Reservoir vent filter trap filled with oil
Optional oil reservoir heater thermostat set to 100° F (40° C)
Oil pump rotation checked
Control System
Air pressure sensors properly connected
Monitoring points checked for faults
Current transformer scale factor
Vibration probe wiring checked
Table 3—2. The Installation Inspection Checklist
3—27
Main Drive Motor Installation Items

Before coupling the compressor and main drive motor, it is necessary to perform the following
verifications:
1. Carefully follow all of the motor manufacturer’s instructions (provided under separate cover)
regarding preparation and installation.
2. Verify that the rating voltage and frequency shown on the motor nameplate match the power
supply.
3. “Bump” (energize and quickly de-energize) the motor so that the shaft rotates only a few revolu-
tions, and verify the direction of rotation using the directional arrow on the compressor gearbox
cover. If required, change the phase wiring to reverse the direction of rotation.
4. Verify that motor fastening bolts are properly torqued as listed in Section Two, Compressor
Specifications.
Oil Pump Motor Rotation Verification

It is necessary to verify the correct rotational direction of the auxiliary oil pump motor as follows:
1. Note the arrow indicating the correct rotation direction on the mounting flange between the
pump and the motor.
2. Turn on the oil pump motor and observe the rotation direction of the motor fan. (The correct
rotation is clockwise, as indicated by the arrow.)
3. If the rotation of the motor fan is not clockwise, correct the pump rotation by interchanging two
of the three power phases connected to the motor.
Fan Motor Rotation Verification

This inspection is required to ensure that the fan will move cooling air through the heat exchangers in
the correct direction for maximum performance.
Confirm the correct rotation of the fan motor as follows:
1. Cooling air should flow into the louvered intakes in the lower half of the enclosure door panels and
out through the top of the package.
2. Turn on the fan motor and observe the flow of air through the enclosure.
3. If the rotation of the fan motor is not correct, change the rotation by interchanging two of the
three power phases connected to the motor side of the starter.
3—28
Installation
Lubrication System Flush

Although factory testing includes full operation of the compressor lubrication system, it is necessary to
thoroughly flush the system before the initial startup to clear the system of any contaminants that may
have been introduced during shipment and installation.
1. Fill the reservoir with the Compression Systems TurboBlendTM Lubricating Oil.
2. Verify that the compressor oil temperature is at least 60° F (15° C).
3. If necessary to warm the oil, energize the oil heater (an optional feature not necessarily included
with all units).
4. Circulate the oil for at least 2 hours.
5. Shut off the oil pump after the circulation period.
6. Remove and inspect the oil filter for any signs of contamination.
The Compression Systems service representative must observe this last inspection point and (if
required because of contamination) the changing of the oil filter element before the initial compres-
sor startup.
3—29
Preparing for Startup

Each compressor undergoes comprehensive testing before it leaves the manufacturing facility.
However, after transit and installation, it is necessary to recheck certain items on site. Before the initial
startup procedure, several inspections and adjustments are required to verify that the compressor has
been installed correctly and to be sure that all subsystems are functioning correctly.
To ensure a proper and safe compressor startup and correct operation, a Compression Systems factory
trained and authorized service representative should be present to inspect the site, supervise the final
installation steps, and assist with the startup procedure.
The Installation Inspection Checklist lists the items that the user or installer should complete prior to the
arrival of the Compression Systems authorized startup representative. Should any concerns or questions
develop while executing this list, contact your representative.
WARNING:
Personnel safety and equipment protection must always be primary considerations during
compressor installation, startup, and operation. Failure to follow the safety precautions
throughout this document can result in equipment damage or personal injury
Avoiding Startup Problems

It is the owner’s responsibility to plan for the inspection and initial startup service. Contact your local
authorized Compression Systems service representative several weeks prior to the anticipated on-site
date to arrange for startup service.
Table 3—3 lists common problems or situations that can delay the installation and initial compressor
start-up. The owner/installer should be aware of these items and correct them, if possible, prior to the
arrival of the authorized service representative.
Potential Installation Problems

• Damage during shipment
• Damage from improper lifting or from mishandling
• Earth grounds not in place
• Incorrect or incomplete electrical interface with motor controls
• Incorrectly installed bypass or blow-off valve piping
• Condensate drain piping manifolded together
• Bypass valves not included on condensate drain piping
• Reservoir vent ejector piping improperly installed
• Excessive stresses on inlet, discharge, or water piping
• Temporary inlet pipe screen not available on site (if applicable)
• Correct quantity of TurboBlendTM Lubricating Oil not available on site
• Correct type of motor and/or coupling grease not available on site
• Necessary equipment, tools, supplies, and parts, not available on site
• Necessary labor not available on site
• Technical information (manuals and drawings) not available on site
Table 3—3 Potential Compressor Installation Problems
3—30
Installation
Initial Start-up Checklist

The authorized service representative uses the checklists below during initial compressor startup.
WARNING:
Do not attempt to start up the Turbo Air Centrifugal Compressor until a Compression
Systems authorized service representative has fully checked and approved the compressor
installation. Compression Systems recommends that a trained and authorized service
representative perform the initial startup procedure.
Before Applying Power

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

✔ Check the supplied panel power.
✔ Verify that the control configuration matches the job site parameters.
✔ Verify that vibration probe gaps are correct.
✔ Verify the monitoring points for correct instrument locations and secure wiring.
✔ Verify proper compressor inlet and discharge valve operation.
✔ Verify that all control setpoints are in accordance with Compression Systems guidelines.
✔ Turn-on the oil reservoir vent ejector.
✔ Turn on the auxiliary oil pump motor and coolant fan.
✔ Verify proper oil pump operation. Adjust oil pressure regulator, if required.
✔ Rack in the main drive motor starter.
✔ Pull out the Emergency Stop button on the control panel.
✔ Verify the start sequence status. Correct if necessary.
3—31
Initial Compressor Startup

Following completion of all installation procedures and pre-start checks, an authorized Compression
Systems Service representative uses the checklist below as a guide for conducting the initial compressor
startup.
Preparation
9 Rack in main power to compressor and control panel.
9 Verify status using the control panel screens
9 Verify that the isolating air system block valve is closed.
9 Verify proper operation of compressor inlet and discharge control valves.
9 Establish required vacuum in oil sump by adjusting regulated clean, dry air supply to
the air ejector.
9 Close the condensate drain manual bypass valves.
9 Set the System Pressure setpoint, temporarily, to 0 psi. (This prevents the compressor from
trying to load, on initial start.)
Startup
9 Press Start on the control panel.
9 Measure and make a note of the acceleration time to full speed. When able, adjust the
starting sequence accordingly.
9 Press Unload on the control panel and run the compressor unloaded for approximately
30 minutes.
9 Perform walk-around inspection to check for any air or oil leaks.
9 Periodically check that all operating parameters are at acceptable levels.
Manual Load
9 Open the isolating system block valve, if it is a non-automatic type.
9 Manually load the compressor to its design point and allow to warm up for one hour.
9 Verify proper operation of condensate removal system.
9 Check again for any leaks and for correct values of all parameters.
3—32
Installation
Manual Surge Testing and Offline Control Loop Tuning
9 Perform the Natural Surge Test manually, if possible, and record the results
9 Manually perform the required surge line surge tests per established Compression
Systems service procedures and record the results.
9 Tune the Inlet Maximum Load Control loop at the required amp value
9 Tune the Surge Control loop at the required amp value
9 Tune the Blow Off Discharge Pressure loop at the required discharge pressure
9 Manually perform the required surge line surge tests per established Compression
Systems service procedures and record the results.
Performance Control Parameter Entries
9 Unload the compressor.
9 Enter all Performance Control parameters into the Maestro configuration, including
all surge test values
9 Review all control parameters and check for input errors.
9 Set the proper Operator settings for Maestro.
System Mode Tuning
9 Load the compressor in Automatic control and verify proper compressor operation in the
Automatic mode.
9 Tune the Inlet System Pressure control loop at the required pressure, per established
procedures.
9 Tune the Blow Off Pressure control loop, at the required pressure.
9 Prepare to shut down the compressor
9 Press Stop on the Maestro panel and verify the correct stopping sequences.
Saving the Control Configuration
9 Make final adjustments to Control parameters, if required.
9 Reset the Maestro Operation History.
9 Save/document the final Maestro Configuration.
9 For the Maestro Legend Controller Only, send the final Maestro Configuration to the
Maestro Solution web site archive.
3—33
3—34
Routine Operation
Section Four
Routine Operation
♦ The Operating Data Record
♦ Routine Startup
♦ Routine Shutdown
♦ General Lubrication Requirements
♦ The Compressor Lubrication System
♦ Operational Guidelines
♦ Gearbox and Reservoir Venting
♦ Optional Features
4—1
4—2
Routine Operation
After successful startup, the operator should keep detailed compressor operation and maintenance
records. (Refer to Section Five, Maintenance, for schedules and instructions for routine and periodic
preventive maintenance procedures.)
To assure long life and optimal output from the Turbo Air 2000 Centrifugal Compressor, always follow
the prescribed maintenance procedures. If problems arise, contact a Compression Systems factory
trained and authorized service representative for technical assistance.
The Operating Data Record

Compression Systems recommends keeping an Operating Data Record to list inspections and to store
operating data for trend analysis. Proper use of the record form ensures that each item or procedure
receives recommended periodic maintenance.
4—3
Operating Data Record

General Information
Compressor Number: Turbo Air Model:
Serial Number: Recorded By: Date:
Air System
3 System Air Pressure:
3 Discharge Air Pressure:
3 Inlet Air Filter Pressure Drop:
3 Stage 1 Inlet Temperature:
3 Discharge Air Temperature:
Vibration
3 Stage 1 Vibration:
Lubrication System
3 Oil Temperature:
3 Oil Pressure:
3 Oil Filter Pressure Drop:
3 Oil Tank Vacuum:
Drive Motor
3 Motor Current:
3 Motor Bearing Temperatures:
3 Motor Stator Temperatures:
Miscellaneous
3 Ambient Temperature:
3 Total Running Time:
3 Control Mode:
Table 4—1 Operating Data Record (Typical)
4—4
Routine Operation
Routine Startup
After the initial compressor commissioning and control loop tuning, use the following procedure for
routinely starting the compressor.
Optional features such as Automatic Start, Automatic Block Valve, or other remote features may
affect individual steps below or otherwise have an effect on the procedure in general. Refer to the
instructions supplied with the specific option to determine the appropriate variation(s) of this
routine startup procedure.
Startup procedure
1. Close the intercooler condensate drain bypass valves.
2. Check the oil level in the compressor oil reservoir.
3. Turn on the air ejector supply pressure and adjust appropriately; if necessary.
4. Rack in the drive motor starter disconnect.
5. Start up the electric oil pump and coolant fan.
6. Inspect the compressor for any oil leaks.
7. Open the discharge air system block valve.
CAUTION:
Do not open the air system block valve when the oil pump is not operating. Operation
under such conditions may cause compressor damage.
8. Press the applicable key and verify that the starting sequence parameters are ready.
(See Controls Section for specifics.)
9. Pull out the red EMERGENCY STOP button.
10. Press the Start key. The compressor will go through its starting sequence.
Following this sequence, the compressor will automatically load if the system pressure is below it’s
setpoint.
4—5
Routine Shutdown
Use the following procedure for shutting down the compressor under normal operating conditions.
Optional features such as Automatic Start option, Automatic Block Valve, or other remote features
may affect individual steps below or otherwise have an effect on the procedure in general. Refer to
the instructions supplied with the specific option to determine the appropriate variation(s) of this
routine startup procedure.
Shutdown Procedure
1. Unload the compressor by pressing the applicable key.
2. Allow the inlet valve to close; then press STOP.
3. Close the air system block valve and wait for the sequence to complete.
4. Open the condensate drain bypass valves.
5. Allow the cooling fan and the oil to circulate for at least 30 minutes to remove heat.
6. Stop the electric oil pump.
7. Rack out the drive motor starter disconnect.
8. Turn off the air ejector supply pressure.
CAUTION:
If the compressor is to be shut down for an extended period in a cold environment, drain
all water from the system after shutdown. Even small amounts of water remaining in the
separators or piping can freeze and cause damage.
4—6
Routine Operation
General Lubrication Considerations

Unlike some other types of rotating equipment, high-speed, geared compressors cannot operate, even
for very brief periods, without adequate lubrication. The Turbo Air 2000 Compressor lubrication system
is a self-contained part of the compressor package and is designed to provide a constant supply of
cooled, filtered lubricating oil to the compressor bearings and gear sprays at all times, even during
emergency situations such as power outages.
The main oil pump is mounted directly onto the compressor gearbox and is driven by an extension of
the bullgear shaft. The auxiliary oil pump is driven by a separate electric motor. The system contains all
of the necessary components required to regulate, cool, filter and monitor the oil before it enters the
compressor gearbox. Several optional features, such as dual filters, reservoir heaters and more, are
available as specific conditions justify.
Helpful information about operating, maintaining and troubleshooting the lubrication system is
included throughout this manual. Also refer to Section Two, Specifications, for information about
TurboBlendTM Lubricating Oil, and Section Seven, Parts & Service, for replacement part numbering
details.
4—7
The Compressor Lubrication System

Figure 4—1 is a schematic illustration of the compressor lubrication system showing the normal circula-
tion of the oil through the compressor system. A description of the normal sequence of operation
follows.
Normal Operation
1. The main oil pump [B], driven off of an extension of the bullgear shaft, draws oil from the reservoir
[A], through check valve [N], and cycles it through the lubrication system and the compressor
gearbox. Check valve [C] prevents the oil from being pumped back into the reservoir through the
auxiliary oil pump [M].
2. Excess heat is removed from the oil as it passes through the oil cooler [D].
3. The oil continues on to the oil filter [F] where impurities are removed.
4. In the gearbox [G], the oil flows through a manifold [H] where it is distributed to the bullgear
bearings [I], the pinion bearings [J], and the two gear-mesh spray nozzles [K].
5. The oil flows from the gearbox to the oil reservoir, passing around a baffle arrangement that
breaks down any foam before it enters the rest of the compressor lubrication system.
6. The pressure regulator valve [PR] maintains the correct operating pressure throughout the
lubrication cycle and returns any excess oil to the reservoir.
7. Oil temperature is maintained by the thermostatic Mixing Valve [TR] which can automatically control
oil temperature by regulating the oil flow around the oil cooler, thus keeping the temperature of
the oil entering the compressor constant.
NOTE: The auxiliary pump [M] does not run during normal operation. The main oil pump pro-
vides full compressor oil flow and pressure requirements.
Gearbox
G
Pinion Bearings [J]

Manifold [H]
Gear Spray Nozzles [K]
Bleed
Valve Bullgear Bearings [I]
Regulator
PR
Lube Oil
Reservoir
A
Level Temperature Pressure
Indicator Sensor Sensor
Check Mixing
Valve Main Oil Valve
N Pump B TR Oil Filter
Check
Auxiliary
Oil Pump Valve
M C
Oil Cooler
D
Cooling
Fan
Figure 4—1 Compressor Lubrication System Schematic
4—8
Routine Operation
Operational Guidelines
To obtain the best and safest operation of the Turbo Air Compressor, apply the following guidelines
and recommendations.
Oil Pump Operation

Compression Systems recommends keeping the auxiliary oil pump in continuous operation during
periods of compressor shutdown to ensure proper lubrication at all times. However, in order for this
recommendation to be followed, the oil pump must be electrically isolated from all other compressor
systems.
In instances when for some reason the oil pump is not kept in continuous operation, it should be kept
running for a minimum of 30 minutes after compressor shutdown. This will assure that any excess heat
will be removed from the bearings and gearing.
CAUTION:
Always maintain the proper air supply pressure to the reservoir vent ejector/filter system
whenever the oil pump is in operation. Failure to do so may cause oil leaks, premature
wear, and component damage.
4—9
Gearbox and Reservoir Venting

During multi-geared, centrifugal compressor operation, the action of meshing gears and the rotation
of the bullgear cause air to become entrapped in the lubricating oil. As this air is released from the oil,
it forms an oil-laden mist in the gearbox and the oil reservoir. It is very important that both the gear-
box and oil reservoir are properly vented so that this oil mist is not allowed to escape.
Ejector/Filter
A simple venturi-type ejector/filter system creates a slight vacuum inside the gearbox and oil reservoir.
The required vacuum (8 to 10 in H20 / 200 to 250 mm H20 ) prevents oil or oil mist from migrating out
into the atmosphere and/or creating other oil leaks. The ejector/filter system is illustrated in Figure 4-2.
WARNING:
Introducing water into the oil reservoir will have adverse effects on the lubricating oil and
will cause severe damage to the compressor. Be sure the ejector’s supply air is clean and
dry and the filter is properly maintained.
Clean, Dry
Compressed
Air
Mist FIlter
D
Air
Ejector
3/4” B A
Vent
Check
Trap Valve
Fill
Trap
E Lube Oil
Reservoir
C
Figure 4—2 The Ejector/Filter System
Under normal operating conditions, the Ejector/Filter Arrangement operates as follows:

1. Dry, filtered, compressed air enters the ejector inlet (A) and is transformed into a high velocity
stream in the ejector nozzle (B).
2. Air from the main oil reservoir (C) becomes entrained in this high velocity stream.
3. The resulting pumping action draws the oil-laden air from the reservoir and gearbox and delivers it
to the filter (D), where droplets of oil accumulate and are then returned to the main oil reservoir.
4. The oil return line includes a mist trap (E) before the oil reservoir. This mist trap serves as a vapor
lock to prevent the oil mist from bypassing the filter and escaping to the surrounding area.
4—10
Routine Operation
Optional Features
Although the following components are not required for safe operation of the Turbo Air 2000 Com-
pressor, they will bring added convenience to the overall operation of the lubrication system. If not
included with the initial compressor package, they may be added at any time.
Oil Reservoir Heater

The minimum startup oil temperature for the compressor lubrication system is 60°F (15° C). Therefore,
compressors that are installed outdoors or in unheated buildings may require the use of the Oil
Reservoir Heater option. Such emersion heaters are rated at 1.5 kW and are available in any standard
three-phase voltage up to 600 volts. The heater is installed in the oil reservoir. Figure 4—3 shows the
Oil Heater option.
Figure 4—3 The Oil Heater Option
4—11
Duplex Oil Filter

In many instances, compressed air systems operate on a continuous basis. Since it is frequently inconve-
nient to completely shut down compressor operation to perform a simple maintenance task, Compres-
sion Systems offers the Duplex Oil Filter option. The duplex oil filter eliminates the necessity for com-
pressor shutdown during filter maintenance. (Refer to Section Five, Maintenance, for full instructions
regarding this procedure.) The Duplex Oil Filter option is shown in Figure 4—5.
Figure 4—5 The Duplex Oil Filter
Oil Filter Differential Pressure Monitoring

With this optional feature, a second pressure transducer is installed before the oil filter. (The system’s
standard pressure transducer is located between the filter and the gearbox.) In such instances, the
Maestro Control System is programmed to calculate the differential pressure across the oil filter and to
provide Alarm and Trip functions. The Oil Filter Differential Pressure Monitoring option is particularly
useful when included as part of a predictive maintenance program. Figure 4—6 shows the Oil Filter
Differential Pressure Monitoring option.
Oil from Cooler Oil to Gearbox
Oil Filter
Figure 4—6 Oil Filter Differential Pressure Monitoring Option
Low Oil Level Indicator

With the installation of the Low Oil Level Indicator option (a switch located in the main oil reservoir)
the Maestro Control System will report any oil level in the reservoir that is below a pre-defined level.
The control system then indicates an Alarm condition to alert the operator of the problem.
4—12
Maintenance
Section Five
Maintenance
♦ Daily Inspection
♦ Scheduled Maintenance
♦ Professional Inspection
♦ Filter Maintenance Schedule
♦ Lubrication Schedule
♦ Additional Maintenance
5—1
5—2
Maintenance
The Compression Systems Turbo Air Centrifugal Compressor requires minimal maintenance. However,
monitoring operating conditions on a daily basis is good practice. It allows the operators to become
familiar with a smooth running machine, which enables early detection of potential problems.
As with other types of highly developed machinery, compressors are subject to operational changes
resulting from environmental conditions, wear, or neglect. A plugged condensate drain, unusual
noises, increases in temperature or vibration, and fluid leaks are some examples of operational changes
that signal potential problems. By recognizing and responding to changes in operation you can prevent
unscheduled shutdowns and the expense of unanticipated repairs.
WARNING:
Do not attempt service procedures other than those described in this manual. Even a
minor adjustment, incorrectly performed could cause serious damage. Since the Turbo Air
2000 Centrifugal Compressor is a high technology product, for all other procedures always
consult a Compression Systems trained and authorized service representative.
5—3
Daily Inspection
A proper daily inspection allows the operator to develop a sense for the appearance, sounds, and
other operating conditions of a smoothly performing compressor.
Daily Operator Inspection Checklist

WARNING: Exercise care when in the vicinity of hot surfaces, pressurized air, and high voltages.
Procedures accompanied by the alert symbol require special precautions as indicated.
Operating Data Log
3 Operating Parameters recorded and within specifications
3 Setpoints Checked
Gearcase
3 External surfaces wiped clean
3 No unusual noise or vibrations
3 No oil leaks
3 No air leaks
3 No frayed or worn electrical cables
Intercoolers and Aftercooler
3 Condensate drains functioning properly
3 Dirt buildup on enclosure filters not excessive
3 No air leaks
Lubrication System
3 Proper oil level in oil reservoir
3 Proper oil color
3 No mist from ejector system
3 No oil leaks
Compressor Drive Motor (Inspect visually only—high voltages, temperatures)
3 Properly ventilated
3 No erratic or noisy operation
3 Inspected in accordance with manufacturer’s recommendations
Table 5—1 Daily Operator Inspection Checklist
5—4
Maintenance
Scheduled Maintenance
Table 5—2 lists the intervals for prescribed scheduled maintenance procedures. These intervals may
vary with operating conditions and/or actual hours of machine operation. Some items may require
attention more or less frequently as circumstances dictate.
NOTE: For maintenance of any compressor accessory not shown, refer to the specific maintenance
instructions for that item
Scheduled Maintenance Procedures

When servicing the Turbo Air 2000 Centrifugal Compressor, use only genuine Joy® and Compres-
sion Systems replacement parts and recommended supplies available through Compression
Systems and/or authorized representatives.
Daily:
3 Operating data logged and reviewed
Monthly:
3 Inlet air filter elements inspected, replaced if required
3 Oil reservoir venting system filter elements inspected, replaced if required
3 Compressor bypass valve filter checked (if applicable)
3 Control system operation checked
3 Intercooler/Aftercooler condensate removal system checked
Quarterly:
3 Drive Motor ball lubricated per manufacturer’s instruction*
3 Condensate traps cleaned and inspected
3 Compressor operational data analyzed
3 Lubrication system oil analyzed
3 Verfiy oil heater operation (if applicable)
3 Verify silencer element operation
3 Verify discharge check valve operation
*Refer to the motor instructions for specific interval guidelines.
Table 5—2 Scheduled Maintenance Procedures
Continued on next page.
5—5
Scheduled Maintenance
Table 5—2 continued.
NOTE: For maintenance of any compressor accessory not shown, refer to the specific maintenance
instructions for that item
Scheduled Maintenance Procedures

When servicing the Turbo Air 2000 Centrifugal Compressor, use only genuine Joy® and Compres-
sion Systems replacement parts and recommended supplies available through Compression
Systems and/or authorized representatives.
Every Six Months:
3 Lubricate main drive motor (see motor manual)*
3 Main drive motor maintenance checks completed*
3 Main drive coupling inspected and regreased
NOTE: New hardware coupling bolts recommended.
3 Lubrication system oil tested (change if required)
3 Oil pump motor and fan motor lubricated with recommended grease (if required)
3 Verify operation of main and aux oil pumps
3 Oil system filter element changed
3 Oil reservoir venting system filter element changed
3 Condensate chemically tested
3 Intercooler / Aftercooler condensate removal system cleaned and inspected
3 Verify proper operation of compressor inlet and discharge valves
3 Bypass valve air filter replaced, if applicable
3 Bypass silencer element replaced
3 Discharge air check valve inspected
3 Verify vibration probe gap voltage
3 Test E-stop circuit
3 Verify proper control panel set up
3 Perform surge tests and record results
3 Cooling fan motor ball bearings lubricated
3 Replace the enclosure filter elements
*Refer to the motor instructions for specific interval guidelines.

Table 5—2 Scheduled Maintenance Procedures - continued
5—6
Maintenance
Professional Inspection
An effective preventive maintenance program includes a professional inspection after an established
interval based on jobsite conditions. Table 5— 3 lists items that are typically performed with a
professional service inspection. Contact a Compression Systems trained and authorized service repre-
sentative for those procedures as they are not intended for unauthorized personnel.
Service Inspection Checklist

To be performed with a Compression Systems authorized representative:
Operating Data Log

3 Recent data logs and maintenance history reviewed with customer
Gearcase*
3 Impellers, inlets, and diffusers cleaned and Inspected
3 Gearing visually checked
3 Gearing backlash clearances measured
3 Axial pinion floats measured
3 Clearances between impellers and inlets checked
Intercoolers* and Aftercooler*
3 Coolers inspected, cleaned if required
3 Condensate removal system cleaned and inspected
3 Cooling sensors checked
Lubrication System*
3 Piping connections checked for leaks
3 Oil visually inspected
3 Oil cooler inspected
3 Oil pumps inspected
3 Oil system sensors checked
Filters
3 All filter elements inspected and replaced as required
Control Panel
3 Inspected for proper configuration and operation (adjust as required)
Control Valves
3 Compressor inlet valve inspected and adjusted
3 Compressor modulating blow off or bypass valve inspected and adjusted
3 Discharge air check valve inspected
3 Auto block valve inspected (where applicable)
Drive Motor
3 Main drive coupling inspected and re-greased, if applicable
NOTE: Replace hardware coupling bolts.
3 Motor inspected in accordance with manufacturer’s instructions
*Replacement parts required. Use only genuine JOY® and Compression Systems parts and supplies
available through the Compression Systems and/or authorized representatives.
Table 5—3 Service Inspection Checklist
5—7
Filter Maintenance
Different types of filters are located in various parts of the compressor package. The operator must
regularly monitor the condition of these filters and clean or change them as required.
Table 5—4 lists the various filters along with recommended inspection intervals for typical operating
environments. Instructions for each procedure are included in this section.
Filter Maintenance Schedule

Filter: Inspect: Clean or Change:
Inlet air filter elements* Monthly When dirty or after 12 months
Bypass valve air supply filter* Monthly When dirty or after 6 months
Oil reservoir venting system* Monthly With misting or after 6 months
Oil system filter element* N/A At Alarm level or after 6 months
*When replacing filter elements, use only genuine Compression Systems products. Refer to Section
Seven, Parts and Service, for more information on parts that are available through your Compression
Systems representatives.
Table 5—4 Filter Maintenance Schedule
Inlet Air Filter

Standard Primary Filter Cleaning
The only reliable method to determine whether cleaning or replacement is necessary is to monitor the
pressure drop across the filter elements. Use this procedure:
Inlet Air Filter Replacement
The TAC-2000 Compressor is supplied with an air filter installed on the air piping located inside the
sound enclosure. The element must be replaced when it becomes dirty and no longer functions
properly.
CAUTION:
The compressor must not be operating when this element is replaced. Operation without
proper filtration may cause compressor damage or malfunction.
Because contamination levels vary in different operating environments, the only reliable method to
determine whether filter replacement is necessary is by measuring the pressure drop across the filter
element. Use this procedure:
1. Install a differential pressure gauge at the connection provided in the piping near the filter hous-
ing.
2. Measure and record the current pressure drop. Compare that with the one initially taken when
the new filter element was installed.
• If the current pressure drop is within four inches (or 100 mm) water column (WC) of the original,
clean reading, continue operation.
• If the pressure drop exceeds the clean reading by more than four inches (or 100 mm) WC, that is
an indication that the filters require replacement.
When replacing filter elements, use only genuine Compression Systems products. Refer to Section
Seven, Parts and Service, for more information on part numbers. Compression Systems recom-
mends that the compressor owner keep a supply of filter elements for use as required, particularly
if the compressor is operating in a dusty environment.
5—8
Maintenance
Bypass Valve Air Supply Filter

(For solenoid unloading bypass valves only)
The solenoid bypass discharge control valve requires clean dry supply air for proper control. The line
filter in the pilot air supply prevents water and other contaminants from entering the valve and fouling
its control mechanism. Use only a Compression Systems replacement filter.
Filter Element Replacement

The replacement procedure is as follows:
1. Shut down the compressor and exhaust any pressure in the bypass valve air supply line.
2. Unscrew the filter canister from its base and separate the filter element by removing the filter
retaining nut.
3. Inspect the canister o-ring seal and replace if worn or damaged.
4. Install the new replacement filter element.
5. Replace the retaining nut (finger-tighten only) and screw the filter canister to its base.
Oil Reservoir Vent Filter

The oil reservoir is vented through an air ejector-filter system that requires a clean dry air supply to
function properly. Moisture that can accumulate in the filter element eventually drains back into the
reservoir, contaminating the lubricating oil. The filter element must be replaced at least every six
months. Use a Compression Systems replacement filter only.
CAUTION:
Water in the oil reservoir adversely affects the lubricating oil and can cause severe dam-
age to the compressor. Be sure the ejector’s supply air is clean and dry and the filter is
properly maintained during periods of high humidity.

Check the exhaust port at least daily. If an oil mist is evident, that is an indication of a clogged filter
element. Using the following procedure, replace the element.
1. Remove the trap line between the bottom of the filter housing and the oil reservoir.
2. Unscrew the retaining nut at the bottom of the housing.
3. Catch any excess oil in a separate container.
4. Slide down the lower housing section to expose the filter element.
5. Remove the nut holding the filter element in place, remove the element, and (being careful not
to over-tighten the retaining nut) install a new replacement element.
6. Inspect the o-ring seals at the top of the lower housing section and in the retaining nut. Replace
the seals if worn.
7. Wipe the housing clean.
8. Begin filter reassembly by pouring a small amount of oil into the fill connection at the top of the
trap line to restore the mist filter trap. The ejector cannot function without this trap.
9. Complete the reassembly.
5—9
Standard Oil Filter Element Replacement

Compression Systems has specially designed bearing and gearing configurations, not found on other
compressors. Regular maintenance of the oil filtration system is critical to the lasting operation of these
sophisticated components. Use the following procedure to replace the standard oil filter element.
CAUTION:
Use only Compression Systems original equipment replacement filters. Use of improper
filters can damage internal compressor components and will void any existing warranties.
Filter Element Replacement Procedure

1. Shutdown and lock-out the compressor.
2. Close the manual isolating block valve.
3. After the compressor is completely stopped, verify that the discharge air pressure is zero, and
then shut off the oil pump.
WARNING:
Do not attempt to remove any oil filter until oil pressure is at zero (O). Hot oil under
pressure presents a safety hazard to personnel.
4. Remove the spin-off oil filter and catch any excess oil in a separate container.
5. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.
6. Install the new filter element by threading it on and continuing to turn it until hand tight, plus
an additional 1/4 turn.
7. After verifying that the oil level is correct, start the pump and inspect for possible leaks.
Duplex Oil Filter Element Replacement

The Duplex Oil Filter option allows for oil filter replacement without shutting down the compressor.
When required, replace the duplex oil filter elements as follows:
WARNING:
Be sure the chamber to be serviced is not being used. Do not attempt to remove the oil
filter element until the oil pressure in the chamber is at zero (O). Hot oil under pressure
presents a safety hazard to personnel.

1. Using an Allen wrench, turn the bleed screw counterclockwise until the screw head touches the
safety plate on the side not in use (opposite the locking pin).
2. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.
3. Unscrew the filter bowl, and remove the old filter element. Catch any spillage in a separate
container.
4. Install the new filter element and replace the filter bowl. Use only a Compression Systems
replacement filter.
5. Depress the balance valve lever until oil begins to bleed through the bleed screw.
6. Turn the bleed screw clockwise until tight. Depress the balance valve lever once more to
pressurize the filter bowl.
5—10
Maintenance
Lubrication
Table 5—5 lists recommended intervals and the products necessary for proper lubrication of various
Turbo Air 2000 Compressor components. Refer to Section Two, Compressor Specifications, for addi-
tional information regarding required lubricants. For ordering information, refer to Section Seven,
Parts and Service.
Instructions for these periodic lubrication procedures are included in this section.
Compressor Lubrication Schedule

Element Interval Lubricant [A]
Main oil reservoir Monitor daily. Compression Systems
Change only as required. TurboBlendTM Lubricating Oil
Oil pump & fan motor bearings Six months Refer to Section 2
Main drive coupling Six months Compression Systems
Coupling Grease
Drive motor ball bearings [B] Refer to Section 2
Notes:
[A] Use only oils and greases recommended by Compression Systems
[B] Refer to the motor manufacturer’s instructions for specific interval guidelines.
Table 5—5 Compressor Lubrication Schedule
Compressor Lubricating Oil

Compression Systems cannot specify a fixed interval between lubrication system oil changes because of
the wide variety of operating conditions that exist. Therefore, daily the operator should check the oil
visually to monitor changes and/or possible deterioration.
If the oil appears darker than normal, there is probably some contamination.
If the oil appears muddy or contains any white emulsion, there is some contamination with water.
Quarterly or as the situation requires, have the oil tested for viscosity, acid, water and other contamina-
tion. A reputable commercial laboratory can easily detect the presence of any such contamination.
Whenever the performance of the lubricating oil is suspect, Compression Systems recommends addi-
tional testing for the presence of enhancing additives in accordance with The American Society for
Testing and Material (ASTM) as defined in Table 2—1, Oil Specification.
CAUTION:
Be certain to use only Compression Systems TurboBlendTM Lubricating Oil for optimum
performance. Use of any incorrect oil can cause extensive damage to internal components
and will void any existing warranties.
5—11
Oil Pump Motor Bearing Lubrication

Examine the compressor installation to determine the type of motor used. Although the standard
Turbo Air compressor oil pump motor utilizes sealed bearings that do not require lubrication, some
non-standard motors do require lubrication. The operator must identify the type of motor used in the
installation in order to determine whether lubrication is necessary.
Inspect the oil pump motor visually. If grease fittings are included on the motor, it will be necessary to
periodically lubricate the oil pump motor. Use good quality, polyurea-based grease, adding 1/4 oz. (7
gm.) to each fitting. Refer to Section Two for acceptable motor bearing greases.
It is not necessary to lubricate the oil pump coupling.
Cooling Fan Motor Bearing Lubrication

The fan motor is not easily accessible for routine lubrication, therefore, hydraulic hoses have been
fitted to the bearings and brought out to two grease fittings located on the outside of the fan hous-
ing just inside one of the enclosure doors. It will be necessary to periodically lubricate the fan motor
bearings. Use good quality, polyurea-based grease, adding approximately 1/4 oz. (or 7 gm) to each
fitting.
CAUTION:
1. Do not grease more often than after 4000 hours of operation.
2. Too much grease or injecting grease to quickly can cause premature bearing
failure. Slowly apply the recommended amount of grease, taking one minute or
so to apply.
3. Keep grease clean. Mixing dissimilar grease is not recommended.
Fan Housing
Fan motor
grease fittings
Figure 5-1 Fan Motor Grease Fittings
Main Drive Coupling Lubrication, Geared Coupling

It is necessary to lubricate the main drive coupling every six months (maximum) to meet the recommen-
dations of the manufacturer. The six-month intervals may vary somewhat depending on what is
required to be in keeping with good operating practices in any specific application. (For additional
information on lubricant requirements, refer to Section Two, Compressor Specifications.)
CAUTION:
Before starting this procedure replacement nuts should be on hand. (Crimp nuts are used
and have limited ability to re-torque. As a precaution they should be replaced.)
When lubricating the main drive coupling, do not use grease other than that described in
Section Two of this manual. Since other products may cause premature wear and damage,
be sure to use only the grease that was specifically formulated for this purpose.
5—12
Maintenance
Re-grease the main drive coupling as described in the following procedure.
WARNING:
Before beginning this procedure, be certain to lock out the main power supply and to close
the discharge block valve. Failure to follow these basic safeguards may cause serious
personal injury.
1. Remove the coupling guard.
2. Remove the coupling flange fasteners and separate the two sleeves.
3. After sliding the sleeves back enough to expose the gearhubs, use a rag or stiff brush to remove as
much as possible of the old grease from the gearhubs and sleeves.
4. Inspect the gear teeth and o-ring seals for signs of wear or other damage. Replace, if required.
5. Using the palm of the hand, work approximately ½-pound (0.25 kg) of fresh coupling grease into
the gear teeth of the hubs and sleeves, making sure that the hub and sleeve teeth are coated
thoroughly.
6. Taking care not to damage the o-ring seals and carefully engaging the teeth, slip the sleeves back
onto the hubs, replace the flange gasket, and align the flange bolt holes.
7. Secure the sleeves, and carefully tighten the fasteners (with replacement nuts) uniformly to the
torque value shown in Section Two of this manual.
CAUTION:
Do not use the plugs provided on the coupling sleeves when greasing the Turbo Air 2000
Compressor coupling. Although plugs for grease fittings are provided in both coupling
sleeves, those plugs are intended for greasing other applications of this model coupling
only. Follow the procedure described above for proper drive coupling lubrication.
8. Clean any excess grease from outside the coupling and/or shafts, and check the coupling for free
movement back and forth. Total travel should be approximately 0.100” (2-3 mm). The inability to
obtain free movement is an indication of a hydraulic-lock caused by too much grease being forced
into the coupling.
9. If the coupling does not float freely for approximately 0.100” (2-3 mm), correct the interference as
follows:
• Remove the coupling flange fasteners.
• Separate the sleeves until the gearhubs are exposed.
• Remove some of the excess grease.
• Reinstall the flanged sleeves.
• Torque the fasteners to the specified values.
• Verify that the coupling moves freely.
10. Replace the coupling guard.
Main Drive Motor Ball Bearing Lubrication

The Turbo Air 2000 Compressor is driven with a squirrel-cage induction motor with greaseable anti-
friction bearings. Lubrication of anti-friction bearings should be done as a part of a planned mainte-
nance schedule. Refer to the motor manufacturer’s instructions in the Supplemental Data section in
the back of this manual for specific interval guidelines for establishing a motor maintenance schedule.
Grease recommendations and maintenance procedures are also included in the motor Instruction
Manual.
CAUTION:
Do not use excessive amounts of grease. Over-greasing may cause bearing and/or motor
failure.
5—13
Additional Maintenance Procedures

In addition to periodic inspections and maintenance of the filter and lubrication systems, some
maintenance will also be necessary on an “as required” basis.
Instructions for each follow.
Other Maintenance Procedures

Procedure: When Required:
Intercooler/aftercooler cleaning* With elevated interstage air temperatures
Condensate drain cleaning Quarterly, or sooner if required.
Oil cooler cleaning* With elevated oil temperature
Inlet valve and blow off valve inspection At 6-month intervals
Discharge air check valve inspection At 6-month intervals
Additional main drive motor items Per manufacturer’s instructions
*Indicated procedures require the use of parts available through your authorized Compression Systems
representative.
Table 5—6 Other Maintenance Procedures
Cleaning
Before doing so, check for other possible causes of an increase in air temperatures:
1. Verify that ambient conditions are not above compressor design parameters.
2. Be sure the temperature sensors are functioning properly.
3. Be sure that all condensate drains are functioning properly.
Condensate Drain Cleaning

All the components within all condensate removal lines on the compressor should be inspected regu-
larly and cleaned as needed. Proper operation of the condensate removal system is among the most
commonly overlooked preventive maintenance items in compressed air systems, and as a result, conden-
sate build-up within intercooler chambers is likely to damage aluminum fins of the bundle.
Furthermore, condensate carry-over from one stage can harm inlets, diffuser plates, and impellers of
stages downstream.
CAUTION:
Always clean and inspect the condensate removal system following any intercooler clean-
ing procedures.
5—14
Maintenance
Compressor Inlet and Discharge Valve Inspections

Both the inlet throttle valve and the bypass valve of the Turbo Air 2000 Compressor are fitted with
electric actuators. While these valves do not normally require regular formal maintenance procedures,
proper attention to preventative maintenance will extend valve life and unscheduled shutdowns of the
compressed air system.
Under normal operating and environmental conditions, each valve should be inspected annually.
Inspect the valve actuators as described in the following procedures:
WARNING:
personal injury.
1. Remove the actuator cover.
2. Excessive moisture should not be present inside the SmartStep enclosure. This can lead to electrical
or mechanical problems.
3. Misalignment of the load coupling to the output shaft can cause excessive side loading which can
reduce the life of the SmartStep. Misalignment is the primary cause of premature component
wear and resultant problems.
4. Insure that all wiring and ground wires are in good condition and tight clean connections are
made.
5. Reassemble the actuator cover onto the housing base.
6. Verify the integrity of the actuator housing by making sure that sealing bolts are tight, the housing
itself is not cracked or damaged in any way.
5—15
Discharge Air Check Valve Inspection

Proper operation of the discharge air check valve is critical for compressor protection during unloaded
operation or compressor shutdown. The high quality check valve supplied with the compressor pack-
age is designed for long life and has low maintenance requirements. However, it is subject to eventual
wear over time. Therefore, it is recommended that the check valve be periodically inspected to assure
optimal performance at all times.
Use the procedure described below to inspect the discharge air check valve at least every six months.
For severe environments, more frequent inspections are recommended. If the inspection reveals a
faulty valve, it is necessary to replace the entire valve. Reconditioning this type of valve is not recom-
mended.
WARNING:
Before unfastening the air piping fittings for the discharge air check valve inspection, be
certain that the motor starter is locked out, that the air system block valve is fully closed
and secure, and that both sides of the check valve are properly vented. Rapidly escaping
pressurized air is capable of causing serious personal injury.
1. Remove the flange bolts and remove the discharge air check valve from between the compressor
and discharge piping flanges. Note: Only one half of the studs need to be removed and the others
loosened.
2. Examine the interior of the valve and valve seat for any signs of wear, including chatter marks,
burrs, and/or any other signs of deterioration.
3. Inspect the valve swing arm and shaft for signs of wear, and verify freedom of movement. Also,
inspect the flange gaskets and replace as necessary.
4. If any problem is detected, replace the check valve at this time; otherwise, the original valve may be
reinstalled.
5. Check the flow arrow on the body before inserting the valve between the flanges. Valve disc
should swing open in the direction with the flow arrow.
6. Pipeline flanges must be parallel and have the same or compatible pressure class rating as the valve.
7. There must be no obstructions in the flange or pipe bore as this would prevent the valve from
opening fully.
8. Install the check valve between the flanges with the flow arrow pointing downstream of the
compressor (in the direction of air flow). Re-install and fasten all flange hardware.
DANGER:
Before restarting the compressor, be sure that the discharge air check valve is correctly
positioned. Improper installation of this valve will result in compressor damage and/or
personal injury.
5—16
Maintenance
Bypass Valve Recirculation Silencer Replacement

The function of the bypass valve recirculation silencer is to reduce compressor noise levels during
periods of reduced air demand. At such times, the bypass valve is either partially or completely open,
and therefore, air will pass through the silencer.
Overtime, after this air passes through the silencer, the silencer will inevitably become fouled and
plugged with minute airborne dust and contaminants. This restriction will eventually reduce the
silencer’s ability to bypass air efficiently.
It is therefore necessary to replace the silencer element at periodic intervals as part of an established
preventative maintenance program. Compression Systems recommends replacement of the bypass
recirculation silencer whenever the inlet air filter elements are replaced or at least every six months.
When replacement becomes necessary, use the following procedure:
WARNING:
personal injury.
1. Open the filter housing and remove the filter element.
2. Using a large adjustable wrench or pipe wrench, unscrew the silencer element.
3. Replace the element with new Compression Systems parts.
4. Reinstall or replace the filter element if needed.
Additional Main Drive Motor Maintenance

Preventive maintenance must be performed on the main drive motor, in addition to those motor
bearing lubrication items described in the Lubrication portion of this Section.
Refer to the motor manufacturer’s supplied instruction for specific requirements and procedures.
CAUTION:
Failure to comply with the motor manufacturer’s-specified preventive maintenance re-
quirement can result in extensive equipment damage. Improper or inadequate motor
maintenance procedures can void all existing warranties.
5—17
Heat Exchangers
A decrease in heat exchanger performance is an indication that it may be necessary to clean the
intercoolers, aftercoolers and / or oil cooler.
The best indicator of the performance level of the intercoolers and aftercoolers is the approach tem-
perature. This is defined as the difference between the temperature of the compressed air leaving the
heat exchanger and that of the cooling air entering the fan, or the ambient temperature around the
compressor enclosure. Record that information for all heat exchangers when the compressor is first
installed and operating at full load. When an approach temperature increases by 15ºF - 20ºF (8ºC -
10ºC) above the original level, or when an Alarm conditions occurs as a result of high interstage
temperature, that is an indication that it may be time for cleaning.
In the case of the oil cooler, however, the approach temperature cannot be used to determine a
decrease in cooling capacity. The oil cooler should be cleaned whenever the intercoolers and
aftercooler are cleaned, or when the compressor goes into an Alarm condition as a result of high oil
temperature.
Other factors may also sometimes contribute to decreasing heat exchanger performance. Therefore,
before cleaning the heat exchangers:
• Be sure that they are getting the required airflow across them. Check that the enclosure inlet filters
are not plugged or blocked, and that the fan is operating properly.
• Be sure that the temperature measuring instrumentation (RTD’s) is functioning properly.
• Be sure that the condensate drains are also functioning properly.
When it becomes apparent that cleaning is necessary, keep in mind that separate techniques are
utilized for the outside surfaces and internal passages of the heat exchangers.
• External Fins The external finned surfaces of the heat exchangers must be cleaned using a high
pressure air stream. Steam or a pressurized water stream may also be applied. Never use a caustic
compound for cleaning. The heat exchangers are an all aluminum construction. Caustic solutions
will corrode the fins.
• Internal Passages The internal passages may require soaking and flushing with high pressure water
in the direction opposite of the air flow when in service. Cleaning of the internal passages are not
normally necessary unless the air being compressed is not being properly filtered. Disassembly of the
heat exchanger package and replacement gaskets are necessary when cleaning the internal passages.
Instructions for cleaning both the external and internal surfaces of the heat exchangers are included
here. Refer to Section Seven, Parts and Service, for complete information on replacement gaskets
when the coolers are disassembled for cleaning.
5—18
Maintenance
Intercoolers, Aftercooler and Oil Cooler Cleaning

External Surfaces:
When it becomes necessary to clean airborne contaminants from the external surfaces of the heat
exchangers, use compressed air, pressurized water, or steam. The external, finned-surfaces of the heat
exchangers may be cleaned in place. Loosen and clear away any dirt or debris as follows:
WARNING:
Always wear eye protection and protective clothing and observe proper safety precautions
when using compressed air, pressurized water, or steam. Failure to heed this requirement
may cause personal injury.
1. Shut down the compressor, lockout power to the compressor Control Center, close the system block
valve, and allow the hot surfaces of the compressor to cool before beginning maintenance.
2. A “quick clean” can be accomplished without removing the coolers by simply spraying down from
above the enclosure with pressurized air, water or steam. Clean the fins by passing a 30 - 40 psi ( 2.0
- 2.5 bar ) air stream across them. If compressed air is not available, low-pressure steam or a pressur-
ized water spray may also be used to clean the fins. Never use a caustic compound for cleaning.
Caustic solutions will corrode the fins.
CAUTION:
The coolers are an all aluminum construction. Exercise care by not standing on or placing
heavy objects on top of the enclosure or the cooler cores themselves when cleaning.
3. The dirt and debris that has been washed down onto the compressor should be cleaned away by
opening the enclosure doors and spraying the compressor with the same medium used to clean the
heat exchangers.
4. When a more thorough cleaning is required and for best results, remove each individual cooler from
the enclosure assembly. Clean both sides of the exchangers in the fashion described above. Again,
never use caustic solutions. A medium bristle brush may be used to help loosen imbedded dirt from
the fins.
NOTICE:
Replacement gaskets and seals may be necessary when the heat exchangers are removed
for service. Use on genuine Compression Systems parts and supplies that are available
through authorized representatives or directly from Compression Systems. (Refer to
Section Seven, Parts and Service, for additional information regarding inspection kits.)
5. Access to both sides of the oil cooler will become available with the removal of the air coolers.
Therefore, it may not be necessary to remove the oil cooler for a thorough cleaning. However, if it is
necessary to remove the oil cooler, first drain the oil by loosening both hose connections. Be prepared
to catch the oil with appropriate equipment. To aid in releasing all of the oil from the cooler, remove
all mounting bolts and lift one end of the cooler opposite the chosen drain side. Also realize that
cooler oil will flow more slowly than warmer oil.
5—19
Intercoolers and Aftercooler Cleaning

Internal Surfaces:
When the heat exchangers have been removed for external surface cleaning, use the opportunity to
clean the internal passages in the following manner:
1. Use the same pressurized air, water or steam that was used on the external surfaces to clean the
internal fins.
2. Start by first directing the high pressure spray into the discharge nozzle of each cooler.
3. It may also be helpful to reverse the direction of the high pressure spray several times to be sure that
all dirt is loosened and removed
4. Reassemble the heat exchangers making sure that all seals and gaskets are in good condition and
properly positioned. Reattach all air and oil lines making sure that all fasteners are properly
tightened.
Cooling Fan Cleaning and Repair

The fan should be cleaned as necessary to remove accumulated dust, dirt and other foreign matter
which may collect on the blades or other fan parts. The fan may be cleaned in place when the heat
exchangers cores have been removed. Standard industrial cleaning solutions may be used. If rust or
corrosion is found, the affected area should be thoroughly cleaned and refinished.
Blades:
If one of the blades on the propeller are damaged, it is recommended that the entire blade assembly
be replaced or returned to the Compression Systems for necessary repair and rebalancing. Detach the
shaft from the X-brace on the fan frame and return the complete propeller, bearing assembly and
shaft. For convenience in shipment, individual blades may be removed from the fan pulley.
Bearings:
Field replacement of the fan bearings is not recommended. Return the entire blade assembly to
Compression Systems for repairs.
Motor:
Only an authorized motor repair station should perform motor repairs. Contact the motor manufac-
turer for locations of repair stations, or contact Compression Systems for the proper replacement.
5—20
Troubleshooting
Section Six:
Troubleshooting
♦ How to Use the

Troubleshooting Guide
♦ How to Request Assistance
♦ Alarm and Trip Functions
♦ Drive Train Troubleshooting
♦ Control System Troubleshooting
♦ Air System Troubleshooting
♦ Lubrication System Troubleshooting
6—1
6—2
Troubleshooting
This section includes suggestions that are designed to help answer questions or solve problems that
may be encountered during operation of the Turbo Air 2000 Centrifugal Compressor. For troubleshoot-
ing purposes, the compressor installation is divided into four subsystems. These, along with relevant
components or conditions, are shown in Table 6—1.
Compressor Installation Subsystems

The Drive Train
• Compressor gearbox
• Main drive motor
• Main drive motor starter
The Control System

• The Maestro Control Panel
• Instrumentation
• Control valves
• Motor overload
• Control performance
The Air System

• Piping
• Filters
• Other air path components
The Lubrication System

• Oil leaks
• Oil mist
• Temperature discrepancies
• Pressure discrepancies
Table 6—1 Compressor Installation Subsystems
For each of the above subsystems, there is a corresponding subsection in the Troubleshooting Guide.
The suggestions included in the subsections will enable the operator to properly identify and correct
most problems. It may also be helpful to consult Section Two, Compressor Specifications, as well as any
engineering drawings supplied separately.
6—3
How to Use the Troubleshooting Guide

The Troubleshooting Guide that follows contains information compiled with the assistance of Compres-
sion Systems Field Service supervisors. It is broken down into four subsections, one for each of the
subsystems of the compressor installation. Each of the four subsections lists conditions that may be
encountered during compressor operation. At the right of each Condition entry is a second list that
mentions possible causes for that condition in order of likelihood. In the majority of cases, the operator
should be able to quickly identify and solve most problems.
Some of entries listed under the Possible Causes column may also appear in bold face (for example:
Motor Overload). In such instances, the operator should refer to that entry under the Condition list to
explore additional troubleshooting options. If this does not yield positive results, the operator should
then return to the original Condition list and continue to troubleshoot until the correct solution is
determined.
If a problem still remains after considering all the Troubleshooting Chart suggestions, contact a
Compression Systems factory trained and authorized service representative for additional
assistance and advice.
DANGER:
When problems are encountered which are beyond the scope and experience of operating
personnel, always request assistance from a Compression Systems factory trained and
authorized service representative. The Turbo Air 2000 Centrifugal Compressor is a high
technology product, and improper servicing presents the risk of equipment damage and/or
personal injury.
6—4
Troubleshooting
How to Request Assistance

Compression Systems has established a network of factory trained and authorized distributors and
service representatives throughout the United States and around the world. When additional guidance
or help is required, contact one of these representatives. (For additional information about parts and
service, refer to Section Seven, Parts and Service.)
WARNING:
For specialized service procedures, always use the services of a Compression Systems
trained and authorized service representative and only genuine Compression Systems and
JOY® replacement parts. Failure to heed this warning could seriously jeopardize the quality
of the repair or replacement.
For advice or service help, always contact your local authorized Compression Systems sales and service
representative. Refer to Section Seven, Parts & Service, Aftermarket Support, for the name and
address of your local representative.
6—5
Alarm and Trip Functions

If compressor-operating parameters deviate from normal tolerances, the Maestro Control System will
activate one of two levels of compressor protection.
• Alarm. An Alarm condition is a warning about a compressor operating condition that is

outside of normal operating limits. The Alarm is intended to alert the operator to a condition that
merits investigation, but does not present an immediate danger, or prevent the compressor from
operating.
• Trip. A Trip condition is a protective measure initiated by the controller to safeguard the
compressor. A compressor Trip condition requires immediate troubleshooting and correction
before the compressor can be safely put back into operation.
In either instance, when an abnormal condition occurs, the Maestro Control Panel will automatically
revert to the Protection History Screen where the most recent event will be positioned at the top of
the screen indicating date, time, type, description, instrument tag number, and data involved in the
event.
Operator Response to an Alarm or Trip Condition

In the case of a compressor Alarm or Trip condition, the operator should respond as follows:
1. Identify and assess the nature of the Alarm or Trip message that appears on the control panel
display.
2. Acknowledge the alarm and to turn off any external devices installed to alert the operator. The
source of the alarm is maintained in the Protect History file for future review.
3. Review the current monitoring point information and its relationship to the Alarm and Trip set
points.
4. Analyze the information, and then take any appropriate action(s) as required to prevent further
deterioration of the Alarm condition to a dangerous level. In the case of a Trip condition, it is
necessary to correct the cause of the Trip before attempting to restart the compressor.
For more details on using Maestro Troubleshooting Tools, see the Controls Section.
6—6
Troubleshooting
Drive Train Troubleshooting

Condition: Possible Causes:
Main Drive Motor Starter

Overload Relay Trip
Motor being started too frequently

Motor overloaded
Low line voltage
Overload relay not adjusted properly
Relay incorrect

Fuses Blowing
Short in the serviced circuit

Jogging or too frequent starting
Fuse damaged internally due to improper handling

Contactor Inoperative
Control Circuit Fuse Blown

Overload Relay Fuse Blown
Main Fuse Blown\
Incoming power line not energized
Main contactor coil faulty
Control power transformer defective
Overload Relay Tripped or defective
Control power supply voltage too low
Control voltage incorrect
Mechanism jammed
Wiring incorrect
Motor Vibration/Unusual Sounds
Starter malfunction
Foundation bolts loose
Other mechanical part(s) loose
Excessive or unbalanced voltage
Lubrication inadequate or excessive
Dirt on fan
Dirt in air gap
Bearings worn
Misalignment
Drive coupling worn
6—7
Drive Train Troubleshooting...continued

Motor Overheating
Control settings improper

Ambient temperature too high
Ventilation inadequate
Failure to properly cool down motor between starts
Voltage low, high, or unbalanced
Incorrect CT - Size
Lubrication inadequate or excessive
Ground inadequate
Connections improper
Wiring improper
Starter malfunction
Dirt in air gap
Windings shorted
Single phasing
Motor seized
Compressor setpoints improper
Gearbox Oil Leak(s)
Ejector trap not filled

Ejector pressure incorrect
Reservoir vent filter clogged
Splitline seal faulty
Oil seal malfunction
Seal damaged
Compressor Vibration
Sensor Reading Faulty
Wiring in control panel incorrect
High Oil Temperature
Low Oil Temperature
Low Oil Pressure
Oil type incorrect
Oil contaminated
Surging
Motor Vibration
Misalignment
Drive coupling damaged and/or worn
Impellers dirty or damaged
Rotor cartridge malfunction
6—8
Troubleshooting
Control System Troubleshooting

Compressor Start Failure

Drive motor starter not racked in
EMERGENCY STOP button depressed
Start permissives not met
Control panel inoperative
Main power fuses blown or faulty
Drive motor starter malfunction(s):
Thermal overload relays
Main contactor·
Power fuses
Control transformer
Wiring
Start / Stop circuit faulty
Current transducer circuit faulty
Compressor Trip condition (corrective action required)
Motor windings shorted
Motor seized.
EMERGENCY STOP Message
EMERGENCY STOP button depressed
Compressor tripped by external device
Start / Stop circuit faulty.
Wiring to control panel faulty
Control panel power supply voltage(s) incorrect
Vibration probe incorrectly gapped
Pressure sensing line defective
Sensor failed.
Control Panel Inoperative
Power to panel interrupted
Main Logic Module fuse defective or blown*
Wiring connection error
Main Logic Module or User Interface Module failure*
Control Panel Display Inoperative
Main Logic Module inoperative*
Loose Display cable
Contrast set incorrectly
Display backlight failed
Keypad failure.
* Maestro Legend Control Only
6—9
Control System Troubleshooting...continued

Motor Overload
Maximum motor load set point too high
Inlet valve or guide vane assembly inoperative
Inlet valve or guide vane assembly out of adjustment
Thermal overload relay set improperly
Current transducer faulty
Starter problem
Motor problem.
Control Valve(s) Faulty
Wiring from control panel faulty.
Instrument air supply interrupted (pneumatic valves).
Instrument air supply pressure too low (pneumatic
valves only).
Inlet valve or guide vane assembly adjusted
improperly.
Malfunction of mechanical linkage of control valves.
Control solenoid valve malfunction (bypass valve).
Inlet guide vane assembly motor or drive coupling
Malfunction.
Valve failure.
Pneumatic actuator failure.
Current to pneumatic transducer failure (pneumatic
valves only).
Solid state relay failure on Main Logic Module*
(electric actuated only).
Analog output failure on Main Logic Module*
(pneumatic actuated only).
Check Valve Malfunction
Valve oversized
Seat or disc worn or dirty
Disc movement impaired
Compressor Control Performance Abnormal

Set points incorrect.
Sensor reading faulty.
Control valve(s) faulty.
Control system tuning faulty.
* Maestro Legend Control Only
6—10
Troubleshooting
Air System Troubleshooting

High Air Pressure
Low demand
Air Pressure setpoint too high
Low Air Pressure
Air Pressure setpoint incorrect

Maximum Amp setpoint incorrect
Air demand above compressor rating
Inlet air filter dirty or restricted
Ambient air temperature excessive
Impellers dirty
High Air Temperature
Air flow through enclosure doors obstructed

Fan motor not operating properly
Intercoolers and aftercooler fouled
Cooling air bypassing intercoolers and aftercooler
Surging
Surging
Air Pressure setpoint too high

Inlet air filter dirty or restricted
Minimum Amp setpoint too low
High Air Temperature
Bypass silencer fouled
6—11
Lubrication System Troubleshooting

Oil Leak(s)
Connection loose
Filter cartridge loose
Gearbox Oil Leak(s)
Pump shaft seal worn or damaged
Oil Mist
Ejector vent filter clogged

Filter trap not filled
Ejector pressure incorrect
Air flow obstructed

Fan not operating properly
Oil cooler fouled
Thermal mixing valve faulty
Oil heater thermostat faulty
Low Oil Temperature

Thermal mixing valve faulty or missing
Oil heater thermostat faulty or missing
High Oil Filter Differential Pressure
Oil filter element dirty or clogged

High Oil Pressure
Pressure regulator set improperly or malfunctioning

Low Oil Temperature
6—12
Troubleshooting
Lubrication System Troubleshooting...continued

Low Oil Pressure
Oil level too low

Pressure regulator set improperly or
malfunctioning
Fuses in pump motor starter blown or
faulty
Leakage within gearbox
Pump motor starter overloads tripped
Wiring or pump motor or starter incorrect
Pump rotation incorrect
Pump seized
Pump coupling damaged
Pump suction line restriction
Main Oil Pump Malfunction

Pump suction line restricted
Pump coupling damaged
Pump damaged
Pressure regulator set improperly or malfunctioning
Oil level too low
6—13
6—14
Parts and Service
Section Seven:
Parts and Service
♦ Aftermarket Support
♦ The Parts Ordering Procedure
♦ Parts Availability
♦ The Returned Goods Policy
♦ The Periodic Maintenance Parts

Inventory
♦ The Professional Inspection Parts

Requirement
♦ Control System Sensors
♦ Lubrication System Parts
♦ Main Drive Coupling Parts
♦ Heat Exchanger Parts
♦ Condensate Drain Parts
♦ Inlet Filter Parts
♦ Air Piping Parts
7—1
7—2
Parts and Service
Aftermarket Support
As an important part of its commitment to its products and customers, Compression Systems offers full
aftermarket support. The array of aftermarket services includes inspection and repair, availability of
genuine JOY® and Compression Systems parts and recommended supplies, and compressor operator
training seminars at the factory training facilities in the USA or at the user’s site.
WARNING:
Since the Turbo Air 2000 Centrifugal Compressor is a high technology product, do not
attempt inspection, maintenance, or service procedures other than those described in
this manual. For any service of a more specialized nature and service of internal parts,
it is necessary to contact a Compression Systems trained and authorized service
representative.
For parts and/or service, always contact an authorized Compression Systems sales and service represen-
tative or else contact the factory directly.
Parts Coordinator
or
Field Service Department
Cameron’s Compression Systems

3101 Broadway PO Box 209
Buffalo, NY 14225-0209 USA
Phone: (716) 896-6600
Fax: (716) 896-1233
7—3
Parts Ordering Procedure

Since specific compressor models and installations may vary, always be sure to have the following
information available when placing an order:
1. The compressor serial number (included on the compressor nameplate located on the gearbox).
2. The compressor model: Turbo Air Cooled 2000

3. The part description (name).
4. The part reference number.
Parts Availability
When ordering replacement and some spare parts, keep in mind that some parts are not available on
an individual basis, and must always be purchased in sets. Also, in certain instances Compression
Systems may change the part number and/or may substitute a part of equal or greater reliability
without notice.
The Returned Goods Policy

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

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

QtyTurbocompressor
Description Qty Compression Systems
Part Number
Filters:
• Inlet Air Filter, Element [A] [A]
• Oil Reservoir Vent Filter Element 1 AAP1404040-00201
• Oil System Filter Element (Single Filter Type) 1 AAP1404040-00207
• Oil System Filter Element (Dual Filter Type) 2 AAP1401435-00223
Lubricants:
• TurboBlendTM Lubricating Oil (5-gallon / 20-liter pail) [B] AAP1405340-00294
• TurboBlendTM Lubricating Oil (55-gallon / 210-liter drum) [B] AAP1405340-00295
• Oil Sample Kit (12 Bottles and Testing) 1 AAMB797385-00000
• Oil Pump Motor & Main Drive Motor Ball Bearing Grease 1 AAP1405340-00289
• Main Drive Coupling Grease 1 AAP1405340-00264
Parts:
Discharge Air Check Valve (Figure 7—15)
• Check Valve, 3” for 3-Stage Compressors 1 AAP0540024-02140
• Gasket, Valve Flange, 3” 2 AAP0901597-00008
• Check Valve, 4” for 2-Stage Compressors 1 AAP0540024-02141
• Gasket, Valve Flange, 4” 2 AAP0901597-00011
Bypass Silencer (Figure 7—15)
• Silencer Element (3 Stage) 1 AAP0540010-07300
• Gasket, Silencer Flange (3 Stage) 1 AAP1793934-00051
• Gasket, Silencer Flange (2 Stage) 1 AAP1793934-01210
Main Drive Coupling (Figure 7—9)
• O-Ring 2 AAP1406064-04005
• Gasket 1 AAP1406064-04113
Condensate Drains (Figure 7—12)
• Solenoid Valve, 110/120-Volt 3 AAP1401581-01302
• Solenoid Valve, 220/240-Volt 3 AAP1401581-01341
• Check Valve 3 AAP1401581-01303
• Gate Valve 3 AAP1401581-00757
• Orifice, 1/2” NPT 3 AAP3402052-00133
Instrumentation (Figure 7—1)
• Vibration Probe [C] AAP1407030-02006
• RTD [C] AAP3403629-01585
• Pressure Transmitter [C] AAP0540089-00210
• System Pressure [C] AAP0540089-00216
• Drive Motor Current Transformer 1 Contract Specific
Notes: [A] Refer to Figure 7—14, Inlet Air Filter Assembly

[B] Refer to Section 2, Specifications, for reservoir capacity information.
[C] As required.
Table 7—1 Periodic Maintenance Parts and Supplies
7—6
Parts and Service
The Professional Inspection Parts Requirement

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

Description Qty Compression Systems
Part Number
Gearbox:
• O-Ring, First Stage Inlet 1 AAP1406702-00385
• O-Ring, Second Stage Inlet 1 AAP1406702-00381
• O-Ring, Third Stage Inlet 1 AAP1406702-00375
• Seal, First Stage Diffuser 1 AAP1794323-00002
• Seal, Second Stage Diffuser 1 AAP1794323-00001
• Seal, Third Stage Diffuser 1 AAP1794323-00000
• O-Ring Lubricant 1 AAR1409584-00000
• Gearbox Splitline Sealant 1 AAR1405571-00012
Lubrication System:
• Oil Reservoir Vent Filter Element 1 AAP1404040-00201
• Oil System Filter Element (Single Filter Type) 1 AAP1404040-00207
• Oil System Filter Element (Dual Filter Type) 2 AAP1401435-00223
Filters:
• Inlet Air Filter, [B] [B]
Bypass Silencer (Figure 7—15)
Control Valves: (Table 7-15)
Inlet Throttle Valve
• 4-inch: Stepper Design Modulating Actuator Assembly (24 VDC) 1 AAP1401581-01904
• 5-inch: Stepper Design Modulating Actuator Assembly (24 VDC) 1 AAP1401581-01905
Bypass Valve 1 1/2 inch Ball Valve
• Gasket, 4-inch Valve Spacer to 5-inch pipe 1 AAP0901597-00012
• Gasket, Inlet Pipe Flange to Inlet, 5-inch 1 AAP1793934-00050
• Stepper Design Modulating Actuator Assembly (24 VDC) 1 AAP1401581-01906
• Solenoid Design Modulating Actuator Assembly (110/115 VAC) 1 AAP0540008-00965
• Solenoid Design Modulating Actuator Assembly (220/230 VAC) 1 AAP0540008-00968
Check Valve See Figure 7-15
• Check Valve, 3-inch for 3-Stage Compressors 1 AAP0540024-02140
• Check Valve, 4-inch for 2-Stage Compressors 1 AAP0540024-02141
Drive Motor:
Main Drive Coupling (Figure 7—9)
• O-Ring 2 AAP1406064-04005
• Gasket 1 AAP1406064-04113
• Grease, Coupling 1 AAP1405340-00264
Main Drive Motor
• Grease, Ball Bearing 1 AAP1405340-00289
Notes:
[B] Refer to Figure 7—14, Inlet Air Filter Assembly
Table 7—2 Professional Service Inspection Parts and Supplies
7—8
Parts and Service
Control System Sensors
Figure 7—1. Control System Sensors
Item Compression Systems

No. Description Qty Part Number
Standard Instrumentation:
01 Vibration Probe, Stage 1 1 AAP1407030-02006
03 RTD, Inlet Air Temperature, Stage 2 or 3 [A] 1 AAP3403629-01585
04 Transmitter, System Pressure [D] 1 AAP0540089-00216
05 RTD, Oil Temperature 1 AAP3403629-01585
06 Transducer, Oil Pressure after the Filter 1 AAP0540089-00210
07 Tranformer, Drive Motor Current 1 Contract Specific
14 Transmitter, Compressor Discharge Pressure [B] 1 AAP0540089-00210
Optional Instrumentation:
11 Vibration Probe, Stages 2 and/or 3 1-2 AAP1407030-02006
13 RTD, Inlet Air Temperature, Stage 2 [A] 1 AAP3403629-01585
15 Transducer, Oil Pressure before the Filter [B] [C] 1 AAP0540089-00210
16 RTD, Miscellaneous Temperatures (Not Shown) [D] 1-5 AAP3403629-01585
17 Switch, Oil Reservoir Level 1 AAP0540061-00199
18 Transducer, Air Filter Differential Pressure [D] 1 AAP1794463-00127
Notes: [A] Air temperature into the last stage of compression is standard. Alternate
locations are supplied as options.
[B] Located inside control center.
[C] Optional, for filter differential pressure measurement.
[D] Shipped loose for field installation.
Table 7—3. Control System Sensors
7—9
Control System Sensors
01
03
02 04
(GEARBOX COVER)
(OIL/AIR SEAL)
(PINION)
Figure 7—2. Vibration Probe Installation

01 Vibration Probe 1 AAP1407030-02006
02 Retaining Plate 1 AAP1407301-00003
03 Capscrew 1 AAP0902224-00512
04 Tube Fitting 1 AAP1791399-03539
Silicone Adhesive [A] 1 AAR1405571-00005
Notes: [A] Apply adhesive to threads of capscrew and tube fitting.
Table 7—4. Vibration Probe Installation
7—10
Parts and Service
This page intentionally

left blank.
7—11
Lubrication System Parts
Figure 7—6. Lubrication System Components
7—12
Parts and Service
Lubrication System Parts
10
13
12
11
Nut
Filter Housing
13
Nut
Figure 7—6 d. Reservoir Vent Filter Assembly Figure 7—6 e. Duplex Oil Filter Option

01 Oil Pump, Main (shaft-driven) 1 AAP1401428-01499
02 Drive Coupling, Main Oil Pump 1 AAP1402070-00253
03 Oil Pump, Auxiliary (motor-driven) 1 AAP1401428-00648
04 Motor, Auxiliary Oil Pump: (3 HP) 50/60 Hz, CE 1 AAP1402068-00760
190/380-415V,440-480V
05 Drive Coupling, Auxiliary Oil Pump 1 AAP1402070-00164
06 Pressure Regulator (relief valve) 1 AAP1401581-01636
07 Temperature Regulator 1 AAP1401581-01485
08 Oil Pump mounting O-ring 1 AAP1406700-00374
09 Filter: (Single)
- Complete Assembly 1 AAP1401435-00289
- Replacement Element 1 AAP1404040-00207
Reservoir Vent Assembly (Figure 7—6 d):
10 - Ejector 1 AAP1403262-00107
11 - Filter (complete assembly) 1 AAP1794256-00000
12 - Replacement Filter Element 1 AAP1404040-00201
13 - Filter Canister Seal Kit 1 AAP1794256-00001
14 Level Gauge 1 AAP1401582-00008
16 Duplex Filter (Figure 7—6 e): [A]
- Complete Assembly 1 AAA3404748-00190
- Replacement Elements 2 AAP1404040-00223
17 Level Switch [A] 1 AAP0540061-00199
18 Oil Heater [A] (380-480V / 575W) 1 AAP0540063-00287
19 Coalescing Filter Element 1 AAP1404040-00234
20 Electric Regenative Blower (1/3 HP) Consult Factory
Notes: [A] Not all lubrication systems are equipped with these optional features. Most of these features can be
retrofitted after the compressor has been shipped from the factory.
Table 7—6. Standard Lubrication System Components
7—13
Main Drive Coupling Parts
04
02
01
01
BOLT TORQUE VALUES:

Refer to Section 2
Figure 7—9a. Main Drive Coupling Assembly

01 O-Ring 2 AAP1406064-04005
02 Gasket 1 AAP1406064-04113
03 Grease 1 AAP1405340-00264
04 Nut (Replaced on Scheduled Maintenance Intervals) 6 AAP0900490-00201
Table 7—9a. Main Drive Coupling Maintenance Parts
7—14
Parts and Service
Main Drive Coupling Parts

Connecting Bolts / Nuts
Coupling Bolts / Nuts *
Driver Side Bull Gear Side
BOLT TORQUE VALUES:

Refer to Section 2
Figure 7—9b. Main Drive Coupling Assembly

01 Driver Side 1 AAP1406065-00020
02 Bull Gear Side 1 AAP1406065-00021
* Couplings are pre-loaded upon initial assembly. Coupling bolts are torqued.
Table 7—9b. Main Drive Coupling Maintenance Parts
7—15
Heat Exchanger Parts

No Description Qty Part Number
01 Fan Assembly with Motor 1 AAP3797833-00001
02 Fan Motor Only 1 AAP1797834-00001
03 First Stage Air Cooler 1 AAP3797681-00001
04 Second Stage Air Cooler 1 AAP3797682-00001
05 Third Stage Air Cooler 1 AAP3797683-00001
06 Oil - to - Air Cooler 1 AAP3797684-00001
07 Gasket Kit 1 AAMB797862-00000
Table 7--10. Heat Exchanger Parts
07
05
06
04
03
07
01,02
1. Fan assemble with motor

(not shown, located inside housing)
2. Fan motor only
(not shown, located inside housing)
3. First Stage air cooler
4. Second Stage air Cooler
5. Third Stage air cooler
6. Oil-to-air cooler
7. Gasket kit
Figure 7—10 Heat Exchanger Parts
7—16
Parts and Service
Condensate Drain Parts
03
03
04
01
02
Figure 7—12. Solenoid-Operated Condensate Draining System

(One set required for each heat exchanger)

01 Solenoid Valve, 1/2” NPT, 110/120-Volt 1 AAP1401581-01302
01 Solenoid Valve, 1/2” NPT, 220/240-Volt 1 AAP1401581-01341
02 Check Valve, 1/2” NPT 1 AAP1401581-01303
03 Gate Valve, 1/2” NPT 2 AAP1401581-00757
04 Orifice, 1/2” NPT 1 AAP3402052-00133
Table 7—12. Solenoid-Operated Condensate Draining System
01
01
03
T
Drain Line
Heat Exchanger
02
Figure 7—13a. LiquidatorTM Pneumatic Figure 7—13b. LiquidatorTM Pneumatic

Condensate Drain System Condensate Drain Trap

01 Liquidator Drain Trap 1 AAP1797145-00000
02 Gate Valve, 1/2” NPT 2 AAP1401581-00757
03 Check Valve, 1/2” NPT 1 AAP1401581-01303
-- Condensate Kit (containing all the above parts) 1 AAMB408187-00100
Table 7—13. LiquidatorTM Pneumatic Condensate Draining System Components
7—17
Inlet Filter Parts
Figure 7—14. Inlet and Discharge Air Piping Components

-- Filter Element 1 AAP1797870-02501
-- Silencer 1 AAP0540010-07300
Table 7—14. Inlet Air Filter Replacement Parts
7—18
Parts and Service
Air Piping Parts
Figure 7—15. Inlet and Discharge Air Piping Components
7—19
Air Piping Parts

01 Inlet Throttle Valve, 4-inch: Stepper Design [A]
Complete Valve and Modulating Actuator Assembly 1 AAP1401581-01904
01 Inlet Throttle Valve, 5-inch: Stepper Design [A]
02 Gasket, 4-inch Valve Spacer to 5-inch pipe [B] 1 AAP0901597-00012
03 Inlet Gasket, First Stage 1 AAP0907411-00011
04 Bypass Valve, 1-1/2-inch: Stepper Design
04 Bypass Valve, 1-1/2-inch: Solenoid Design
(110/115 VAC 50/60 Hz) 1 AAP0540008-00965
04 Bypass Valve, 1-1/2-inch: Solenoid Design
(220/230 VAC 50/60 Hz) 1 AAP0540008-00968
07 Silencer Element 1 AAP0540010-07300
08 Bypass Hose 1 Consult Factory
09 Pipe Coupling, Victaulic, 4-inch 9 AAP1404961-00604
10 Pipe Coupling Gasket, Victaulic, 4-inch 9 AAP1404961-00603
11 Check Valve, 3-inch for 3-Stage Compressors 1 AAP0540024-02140
11 Check Valve, 4-inch for 2-Stage Compressors 1 AAP0540024-02141
12 Gasket, 3-inch Design Check Valve 2 AAP0901597-00008
12 Gasket, 4-inch Design Check Valve 2 AAP0901597-00011
Notes: [A] Inlet Valve size is determined by compressor rating. The 5-inch valve is used above 175 hp.
Valve is designed with integral seal, gaskets are not required.
[B] Adaptor Spacers are used with 4-inch valve to fit 5-inch pipe.
Table 7—15 Inlet and Discharge Air Piping Components
7—20
Parts and Service
Air Piping Parts

Actuator
Solenoid
Filter Regulator
Lock-Out
Valve
Valve
Body
Figure 7—16. Automatic Block Valve

Assembly
Compression Systems Part Number

Description 115 V / 50-60 Hz 220 V / 50-60 Hz
Block Valve Assembly, 3-inch AAP0540008-00809 AAP0540008-00822
Block Valve Assembly, 4-inch AAP0540008-00800 AAP0540008-00823
Table 7—16. Automatic Block Valve Assemblies
7—21
7—22
Glossary
Glossary
The Turbo Air 2000 Centrifugal Compressor Handbook
Glossary
Air End — the part of the compressor package that includes the gearbox and the air moving
components.
Airflow — the movement of air or process gas through the compressor or the compressed air system.
Aftercooler — a heat exchanger that cools the process air after the final stage of compression.
Alarm — a warning about a compressor operating condition that is outside of normal operating limits.
Blow-Off Valve — an airflow control device that vents compressor discharge air to the atmosphere.
(Also see Modulating Blow-Off Valve.)
BOV — the abbreviation for Blow-Off Valve.
BPV — the abbreviation for Bypass Valve.
Bypass Valve — an airflow control device that vents compressor discharge air back into the inlet pipe
of the compressor.
Bullgear — the main input gear that drives the higher speed pinions.
Bundle — refers to the intercooler or aftercooler heat exchanger core. Consists of the tubesheet, tubes
and baffles.
Check Valve — a device that permits the flow of air, water or oil in one direction only.
Controller, Motor — (See Motor Controller.)
Control Method — the specific technique used by the control system to deliver compressed air to meet
specific process demands.
Control Setpoints — those setpoints that supervise routine compressor operation.
Cooler — device used to remove heat. (See Aftercooler, Intercooler, Oil Cooler, or Panel Cooler.)
Coupling, Main Drive — the device that connects the motor shaft to the bullgear shaft.
Data Log — (See Operator’s Data Log.)
DCS — the abbreviation for Distribution Control System.
Design Standard — the operating condition of the compressor to which the aerodynamic performance
is rated, generally a “worst case” or “hot summer day” condition.
Distribution Control System — a functionally related group of electronic devices used for industrial
machine sequencing and operation.
Diffuser — the component of a compressor stage that helps convert the high velocity airflow into a
pressure rise.
Discharge Pressure — the air pressure measured between the compressor exit and the compressor
discharge check valve.
Display — the screen that presents operating information on the Maestro Control Panel.
Drive End — the end of a rotating machine that contains the drive shaft extension.
Drive Train — the part of the compressor package that contains the main drive motor, the main drive
coupling, and the gearbox.
Ejector — the component that creates a slight vacuum inside the gearbox and oil reservoir to properly
handle oil mist.
EMERGENCY STOP Button — the device on the Maestro Control Panel that serves to immediately
interrupt power to the main motor causing the compressor to stop operating. (For emergency use only.)
FLA — the abbreviation for Full Load Amperage.
Full Load Amperage — the amperage rating of a motor (less Service Factor), the value of which is listed
on motor nameplate.
Gearbox — the parts of the compressor package that contains the gears, bearings, and seals.
Heat Exchanger — a device that is used to cool air or oil during compressor operating.
(See Aftercooler, Intercooler, or Oil Cooler.)
IGV — the abbreviation for Inlet Guide Vane.
Impeller — the aerodynamic component that rotates at a very high speed, thereby increasing the
airflow velocity and imparting energy into the airstream.
Inlet — 1. the component of a compressor stage that covers the impeller and diffuser, thus creating a
very tightly toleranced air passage.
2. the point of the compressor stage at which the air enters.
Inlet Air Filter — a device that removes dirt, dust, and other airborne contaminants from the intake
air before it is allowed to enter the compressor.
Inlet Air Startup Screen — a conical-shaped screen that is placed in the inlet air piping at the initial
startup of the compressor, when required, to stop larger airborne particles from entering the
compressor.
Inlet Guide Vane — a device that throttles inlet airflow to the compressor, while also imparting a
pre-whirl to the airstream.
Intercooler — the heat exchangers that cool the process air between stages of compression.
Keypad — a set of touch-sensitive electrical switches on the Maestro Control Panel that is used to
interface with the control system. (See Function Keypad and Numeric Keypad.)
LED — the abbreviation for Light Emitting Diode.
Light Emitting Diode — a status indicating light on the Maestro Control Panel.
Load or Loaded — any number of compressor operating points where airflow, discharge pressure,
and power consumption are at or near rated values.
MANUAL Control Method — an operating condition during which the position and movement of the
inlet guide vane and blow-off valve are controlled solely by the compressor operator.
Maximum Amp Setting — a setpoint of the control system that is equal to the maximum amperage
draw on the main drive motor.
MBOV — the abbreviation for Modulating Blow-Off Valve.
Mist Filter — a device that collects the oil vapor that is vented from the oil reservoir.
Glossary
Modulating Blow-Off Valve — an airflow control device that vents compressor discharge air to the
atmosphere.
Motor Controller — a device that is used to start, stop and protect electric motors.
(Also referred to as a Motor Starter.)
“Off Design” Operation — a compressor operating condition when the ambient environment is other
than the design standard.
Oil Cooler — the heat exchanger that cools the lubricating oil.
Operator’s Data Log — a periodic record of compressor operation.
Opposite Drive End — the end of a rotating machine that is opposite of the drive shaft extension.
Optical Coupler — an electronic device similar to an electrical relay (also referred to as OPTO).
OPTO — the abbreviation for Optical Coupler.
Panel Cooler — an optional heat exchanger that is used to cool the interior of the Maestro Control
Panel.
Pinion — the gear element to which the impeller(s) are mounted.
PLC — the abbreviation for Programmable Logic Controller.
Programmable Logic Controller — a computer-based device typically used to administer plant-wide
production information.
Potentiometer — an electronic device that varies resistance in an electrical circuit.
Receiver — a storage device (such as a tank, extended length of system piping, etc.) in the compressed
air system used to hold compressed air.
Reservoir, Oil — the tank on the compressor package that is used to hold lubricating oil.
Reservoir Vent — the filtration system comprised of the ejector and mist filter.
Resistive Temperature Detector — a device that is used for temperature measurement.
RTD — the abbreviation for Resistive Temperature Detector.
Scroll — the component of a compressor stage that “collects” the high velocity air exiting the impeller.
Sensor — a device that is used to measure parameters such as, temperature and vibration.
Service Factor — as applied to motors, a factor whereby a motor can be loaded beyond its horsepower
rating without overheating or suffering insulation damage.
Setpoint — a control measurement that protects the compressor or the compressed air system.
(It may or not be capable of being changed by the operator.)
Shaft Alignment — the relative position of the drive train components to each other.
Shutdown — the process of unloading and stopping the compressor.
Silencer — the device that is used to reduce sound levels.
Stage — a set of aerodynamic components including the scroll, inlet, impeller and diffuser.
Starter, Motor — (See Motor Controller.)

Startup — the process of starting and loading the compressor.
Startup Screen — a device that is temporarily installed in the inlet air piping to prevent foreign material
from entering the compressor.
Status Indicator Light — a light on the Maestro Control Panel that indicates a control function.
Surge — a compressor operating condition characterized by a momentary reversal of airflow back
through the compressor.
SysteMiser — an optional control system feature that provides for control of several compressors.
Transducer — a sensor that converts a measured parameter (such as pressure or temperature) to a
voltage output in an established way.
Transmitter — a specific type of transducer that converts a measured parameter (such as pressure)
to a current output (typically 4-20 mA).
Trip — a shutdown initiated by the Maestro Control System to protect the compressor.
Trip Recall Function — a Control Panel Diagnostics function that allows the operator to review
compressor operating data at the time of a compressor Trip condition.
Turndown Range — the extent to which the airflow through the compressor may be throttled without
encountering surge while maintaining setpoint pressure.
Unloaded — an operating condition where airflow through the compressor, and thus power
consumption, are at a minimum.
User Interface — the part of the Maestro Control Panel that allows the user the view data, monitor
compressor operating, and adjust operating parameters (such as setpoints).
“Worst Case” Operating Condition — the ambient circumstances (also referred to as a “hot
summer day”) when the air is less dense and filled with water vapor resulting in adverse compressor
performance.

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Contents

Engineering Data Release

The Turbo Air® Cooled 2000

About This Manual

About This Manual iii

Section One: Introduction

Section Two: Specifications

Section Three: Installation

Section Four: Routine Operation

Section Five: Maintenance

Section Six: Troubleshooting

Section Seven: Parts and Service

In this section, the reader will learn about:

♦ About Cameron’s Compression

♦ The Turbo Air® Cooled 2000

♦ CC V 5-Year Warranty Program

About Cameron’s Compression Systems

Compression Systems is ISO 9001 and ISO 14001 Certified.

To learn more, look us up on the Internet:

Figure 1—1 The Buffalo, New York, USA, Centralized Facilities

The Turbo Air® Cooled 2000 Centrifugal Compressor

The Most Advanced

The Compressor Control Center

The Maestro Control System

Major Component Arrangement

6 1. Horizontally split gearbox casing

Figure 1-1 The Turbo Air Cooled 2000 Centrifugal Compressor

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

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

See page 1-12 for information on CCV SM extended warranty program.

1. Loss of use of productive facilities or equipment.

CCV 5-Year Warranty

THE EDGE IS RELIABILITY

1. On-line registration at www.c-a-m.com

2. The compressor must incorporate TurboBlend™ or equivalent oil at initial startup.

4. Only genuine Compression Systems parts may be used.

5. Maintenance performed by a Compression Systems authorized service representative in accordance

7. Compliance with 5-year warranty terms and conditions.

In this section, the reader will learn about:

♦ General Compressor Specifications

♦ Alarm and Trip Specifications

♦ Compressor Lubricant Requirements

General Compressor Specifications

Abbreviations and Symbols

Package Weights for Installation

Connection Sizes, Ratings and Types (per ANSI)

Item Weight Item Weight

Coupling Bolt Torque Values

Miscellaneous Bolt Torque Values

Lubrication System Operating Conditions

Cooling Fan Motor Starter - Electrical Factors

Discharge Connection Load Limits

Compressor / Motor Control Center

Main Drive Motor Controller / Starter

Maestro Control System

Oil Pump Motor Starter

Oil Heater (Optional) ***

Alarm and Trip Specifications

ALARM and TRIP Setpoints (English Units)

ALARM and TRIP Setpoints (Metric Units)

Compressor Lubricant Requirements

• Acceptable compressor oil

Compressor Oil Selection

Earth ground installed at control panel