Turbo Air 3000 PDF

Contents
The Turbo Air® 3000

Centrifugal Compressor
with the Vantage™ Control System
Compressor Handbook
Cooper Turbocompressor, Inc.

3101 Broadway P.O. Box 209
Buffalo, New York 14225-0209 USA
AAEDR-H-059 Rev. 01
ECO-1910938 May 2003 FWG
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
ii
About ThisContents
Manual
About This Manual

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

About Cooper Turbocompressor 1— 3
The Turbo Air Centrifugal Compressor 1— 4
Safety Precautions 1— 6
Safety Labels 1— 7
Warranty 1—10
Limitation on Liability 1—11
Unauthorized Repair 1—11
Section Two: Specifications

General Compressor Specifications 2— 3
Compressor Lubricant Requirements 2— 6
Section Three: The Control System

The Vantage Control Panel 3— 3
The Vantage User Interface 3— 4
Input or Operational Keys 3— 8
Pratice Exercise 3— 9
Section Four: Routine Operation

General Considerations 4— 3
The Operating Data Record 4— 3
Routine Startup 4— 5
Routine Shutdown 4— 6
Adjusting the System Pressure Setpoint 4— 7
Section Five: Maintenance

Daily Inspection 5— 4
Scheduled Maintenance 5— 5
Professional Inspection 5— 6
Filter Maintenance 5— 7
Lubrication 5—11
Additional Maintenance Procedures 5—17
v
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— 8
Control System Troubleshooting 6—10
Air System Troubleshooting 6—12
Lubrication System Troubleshooting 6—13
Section Seven: Parts and Service

Aftermarket Support 7— 3
Parts Ordering Procedure 7— 4
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 Parts 7— 9
Lubrication System Parts 7—12
Main Drive Coupling Parts 7—14
Heat Exchanger Parts 7—15
Air Piping Parts 7—18
Appendix A: Installation
General Considerations A— 3
The Installation Work Schedule A— 4
Labor, Supplies, Equipment and Tools A— 5
Site Considerations A— 6
Process Air Piping A— 8
Utility Piping A—19
Electrical Interface A—27
Receiving, Lifting, Moving, and Bolting A—30
Preparing for Startup A—32
Preventing Startup Problems A—37
The Inspection Prior to Initial Startup Schedule A—38
The Initial Startup Procedure A—40
Service Assistance A—41
Appendix B: The Lubrication System

General Considerations B— 3
The Compressor Lubrication System B— 4
Vantage Control of Compressor Lubrication B— 5
Operational Guidelines B— 6
Gearbox and Reservoir Venting B— 7
Optional Features B— 8
vi
Contents
Appendix C: Vantage Control System Logic

General Considerations C— 3
Compressor Control Methods C— 4
AUTO-OFFLINE Control C— 7
AUTO-STANDBY Control C—10
AUTO-UNLOAD Control C—12
Compressor Safety Mechanisms C—14
Appendix D: Control System Setpoints Adjustments

General Considerations D— 3
The Operation Setpoint Adjustment Procedure D— 4
Minimum Amp Setpoint Adjustment D— 7
The Protection Setpoint Adjustment Procedure D—11
Appendix E: Control System Initialization

General Considerations E— 3
Control System Initialization E— 4
Analog Channel Initialization E—15
Factory Default Initialization E—23
Appendix F: Glossary
Contract Drawings
Supplemental Data
vii
viii
Introduction
Section One
Introduction
In this section, the reader will learn about:
¨ Cooper Turbocompressor
¨ The Turbo Air 3000 Centrifugal

Compressor
¨ Safety Precautions
¨ Safety Labels
¨ Warranty
¨ Limitation on Liability
¨ Unauthorized Repair
1—1
1—2
Introduction
About Cooper Turbocompressor

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

Http//www.turbocompressor.com
Figure 1—1 The Buffalo, New York, USA, Home Office and Centralized Facilities
1—3
The Turbo Air 3000 Centrifugal Compressor

The Turbo Air 3000 Centrifugal Compressor is a state of the art source of oil-free air manufactured with
the user’s needs in mind. The simple but rugged mechanical design provides many advantages. It
combines the best features of aerodynamic technology to achieve optimum energy efficiency, and it
delivers lower horsepower to cubic feet per minute (CFM) ratios than any other oil-free centrifugal
compressor available.
The Most Advanced

Compressor Components Available
The Turbo Air 3000 Compressor includes internal components which are unique to the industry. Supe-
rior pinion bearings designed for unlimited life and operation at any load. Non-contacting, non-
wearing labyrinth air and oil seals that require no buffering to ensure oil-free compressed air. Impellers
that are an advanced design which combines the best features of a sigma-radial impeller and a back-
ward-leaning impeller. Vaned diffusers that are matched to the impellers for incomparable efficiency.
Finally, inlet guide vanes that are mounted close to the impeller to achieve maximum benefit.
The Vantage Control System

The Vantage control system is standard on the Turbo Air Compressor package. Vantage provides the
compressor owner with high performance solutions through faster response times, improved reliability
and reduced energy costs over other OEM or PLC controllers. This state-of-the-art system is compatible
with all other centrifugal, reciprocating, and rotary screw compressors. The Vantage system was
developed as a result of a strategic alliance formed between Cooper Turbocompressor and Bay Con-
trols.
The various control modes available provide optimal efficiency in even the most demanding applica-
tions, or, when necessary, maintain air system pressure at a uniform level.
NOTE: The Turbo Air 3000 Compressor package is not a complete, stand-alone compressed air
system. To complete the system, additional components (such as main drive motor starter, oil pump
starter, manifolds, inlet air filters, silencers, expansion joints, etc.) are also required. Cooper
Turbocompressor offers a selection of optional equipment as part of the package or as add-ons after
installation.
1—4
Introduction
Other Design Features

Other outstanding design features of the Turbo Air 3000 compressor are shown in Figure 1—2
including:
1. Horizontally split gearbox casing

2. Built-in aftercooler
3. Built-in intercoolers
4. Mounted control panel
5. Self-contained lubrication system
6. Inlet guide vanes (standard)
7. Shaft-driven main oil pump
8. Mounted water manifold (optional)
9. Mounted bypass valve (optional)
6
7
1 3
8
2
3
Figure 1—2 The Turbo Air 3000 Centrifugal Compressor
1—5
Safety Precautions
The Turbo Air 3000 Centrifugal Compressor is a powerful industrial machine that utilizes high-speed
rotating elements and high voltages to produce high air pressures. Therefore, it is very important to
use common sense and extra safety precautions whenever it is in operation as well as when performing
maintenance or making repairs.
Cooper Turbocompressor expressly disclaims responsibility or liability for any injury or damage
caused by failure to observe specified or other common safety precautions or failure to exercise
ordinary caution, common sense, and due care required in operating the compressor even though
not specified herein.
The alert messages shown here appears throughout this manual to indicate those situations and times
when special care is necessary to prevent component harm or personal injury. There are three degrees
of urgency:
CAUTION:
This indicates that there may be the possibility of minor equipment damage.
WARNING:
This indicates that there could be the possibility of minor equipment damage
or personal injury.
DANGER:
This indicates that there will definitely be major equipment damage and/or personal injury
or death if all proper safety precautions are not carefully followed.
The safety guidelines included here are also included on the safety labels affixed to various parts of the
compressor. They alert the user to possible and probable hazards and serve to remind the user of
specific safety precautions. Before using the Turbo Air 3000 Centrifugal Compressor, be certain to
review the safety labels and the following safety guidelines.
WARNING:
Observe all safety precautions included in this manual and on the compressor safety labels.
Failure to do so may cause equipment damage and/or personal injury.
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 Cooper Engineering or Service Depart-
ments.
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
Cooper Turbocompressor warrants that the compressor supplied conforms to applicable drawings and
specifications and that the compressor will be free from defects in material or workmanship for a
period of twelve (12) months from the date of initial operation or a period of fifteen (15) months from
the date of shipment, whichever period expires first.
If, within that period, Cooper Turbocompressor receives written notice from the purchaser of any
alleged defect in or nonconformance of the compressor and if, in Cooper Turbocompressor’s judg-
ment, the compressor does not conform to the original specifications or is found to be defective in
material or workmanship, at its option Cooper Turbocompressor will make restitution in one of these
ways:
1. By furnishing a service representative to correct the defective workmanship.
2. By repairing or replacing the component upon the component having been returned FOB to the
Cooper Turbocompressor factory in Buffalo, New York, USA.
3. By returning the full purchase price of the compressor (without interest) to the purchaser.
Cooper Turbocompressor’s sole responsibility and the purchaser’s exclusive remedy hereunder is
limited to such repair, replacement, or repayment of the full purchase price.
Equipment and accessories furnished by third parties that are not incorporated in the compressor
package manufactured by Cooper Turbocompressor are warranted only to the extent of the original
manufacturer’s warranty to Cooper Turbocompressor.
There are no other warranties—express, statutory, or implied—including those of merchantability

and/or fitness for purpose. Moreover, there is no affirmation of fact or representation that extends
beyond the description of the face of this warranty.
This warranty shall be void and Cooper Turbocompressor shall have no responsibility to repair, replace,
or repay the purchase price of defective or damaged compressors or component parts resulting directly
or indirectly from:
1. The purchaser’s use of repair or replacement parts or supplies not of Cooper Turbocompressor’s
manufacture or which have not been recommended by Cooper Turbocompressor.
2. The purchaser’s failure to store, install, operate, and maintain the compressor according to Cooper
Turbocompressor’s written specifications, drawings, and good engineering practice.
1—10
Introduction
Limitation on Liability
Cooper Turbocompressor’s total responsibility for any claims, damages, losses, or liabilities arising out of
or related to the performance of the products covered hereunder shall not exceed the original pur-
chase price.
In no event shall Cooper Turbocompressor be liable for any special, indirect, incidental, or consequen-
tial damages of any character, including but not limited to:
1. Loss of use of productive facilities or equipment.
2. Lost profits, property damage, and/or expenses incurred in reliance on Cooper Turbocompressor’s
performance hereunder.
3. Lost production, whether suffered by the purchaser or any other third party.
Cooper Turbocompressor disclaims all liability for any and all costs, claims, demands, expenses, or
other damages, either direct or indirect, incident to all property damage arising out of any cause of
action based on strict liability.
Unauthorized Repair
In the event that the owner allows the compressor to be serviced or repaired by unauthorized
personnel, the coverage of the original warranty policy will be automatically terminated.
1—11
1—12
Specifications
Section Two
Specifications
¨ General Compressor Specifications
¨ Compressor Lubricant Requirements
2—1
2—2
Specifications
General Compressor Specifications
Installation Weights
Complete Package with Motor
Compressor Rating (HP*) 400 500 600 700 800

Weight in Pounds 14000 14000 15500 18000 20000
Weight in Kilograms 6350 6350 7000 8400 9300
*HP = Horsepower
Connection Sizes
Connections are to American Standards (ANSI), expressed in inches.
Air Inlet 8” ANSI Pipe Condensate Drain ½” NPT **

Air Discharge 4” Victaulic* Air Ejector ½” NPT **
Air Coolers (Water) 1 1/2” NPT** Control Panel 1” Conduit
Oil Coolers (Water) 3/4” NPT** Pressure Transducers ¼” Fitting
Manifold*** (Water) 3” Victaulic*
*ANSI pipe grooved to accept a Victaulic, or equivalent, pipe coupling.
**NPT = National Pipe Thread (tapered).
***Extra Cost Option.
Discharge Connection Load Limits

English Metric
Maximum Allowable Force 350 lbs 1500 N
Maximum Allowable Moment 500 ft-lbs 675 Nm
Bolt Torques
Unless otherwise noted, all bolts must be torqued to the following. These values are based on clean, unlubricated threads.
Bolt Diameter Torque Range

(inch) (mm) (ft-lbs) (Nm)
3/4 20 143-157 195-210
7/8 22 192-212 260-285
1 25 285-315 385-425
Cold Alignment Specifications for Main Drive Motors

Recommendations for cold field alignment, taken at compressor hub
0.0000 0.000
+0.002 Face +0.001 +0.005 RIM
+.003 +0.007
Recommendations For Cold Field Alignment, Take at Motor Hub
0.0000 0.000
+0.001 Face +0.002 -0.002 RIM -0.005
+0.003 -0.007
2—3

Cooling Water Requirements
The following represents total cooling water requirements for the compressor package including the built-in
aftercooler and oil cooler. The values exhibited represent “worst case” conditions. Therefore, well maintained
heat exchangers will exhibit substantially better performance with less water
Compressor Rating (hp) 400 500 600 700 800

Water Flow (gpm) 105 120 135 135 135
Water Flow (lps) 7.5 8.5 9.5 9.5 9.5
Water Pressure Drop (psi) 6.0 9.0 12.0 12.0 12.0
Water Pressure Drop (bar) 0.42 0.62 0.83 0.83 0.83
Abbreviations: hp = horsepower gpm = gallons per minute lps = liters per second
psi = pounds per square inch bar = metric unit for fluid pressure
Water Quality Requirements - Cooling service requires that the water be low in suspended solids to prevent fouling, low
in dissolved solids to prevent depositions and erosion, free of organic growth, and free of chemicals that exhibit corrosive
properties to the copper tubes used as standard in the compressor heat exchangers. (Other tube materials with various
chemical resistances are available as options. Consult your authorized representative or Cooper Turbocompressor Sales
Department directly.)
Coupling Bolt Torque Values

English Metric
100 ft-lbs 135 Nm
Lubrication System
English Metric
Reservoir Capacity 55 gallons (USA) 210 liters
Minimum Reservoir Temperature Prior to Startup 60°F 15°C
System Operating Temperature 120°F 50°C
System Operating Pressure 120 psig 8.3 barg
Air Ejector Pressure Range 25-30 psig 1.7-2.0 barg
Lubricants
Use Type Amount
Compressor Turbine Oil* 55 gallons (USA)
Main Drive Motor Bearings** Grease* 1 lb (0.5 kg)
Main Drive Coupling Grease* 1 lb (0.5 kg)
Inlet Guide Vane Drive Screw Grease* 1 lb (0.5 kg)
*Refer to text for complete description and recommendations.
**Anti-friction bearings only.
2—4
Specifications
Control Housing Mechanical Specifications

Attribute English Units Metric (ISO) Units
Height 24 inches 610 mm
Width 20 inches 508 mm
Depth 7 inches 178 mm
Weight: 55 pounds 25 kg
Vantage Electrical Specifications

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 1.0 KVA
Location Classification (per USA Standards):
Standard NEMA 4 (outdoor: watertight & dustproof)
Optional NEMA 4X (NEMA 4 with corrosion resistance)
Optional Class I, Groups C & D, Division 2 (limited hazardous)
Environmental
Temperature:
Operating Range* 32° to 140°F 0° to 60°C
Storage Limits -4° to 140°F -20° to 60°C
Humidity:
Operating Range 5 to 95% Relative Humidity (Non-Condensating)
Storage Range 0 to 100% Relative Humidity (Non-Condensating)
*Panel heaters and coolers are available options.
Safety Approvals (optional)

UL (USA) CSA (Canada) CE (Europe)
Other Package Electrical Requirements

Main Drive Motor* Furnished separately
Oil Pump Motor* 5 hp (3.5 kw) 460V/3F/60Hz ***
Oil Heater (optional)** 1.5 kw 460V/3F/60Hz ***
*Starter Required.
**Magnetic contactor required above 480 volts.
***Other voltages are available. Must be specified at time of order entry.
2—5
Compressor Lubricant Requirements

The user must obtain the following required lubricants for use with the Turbo Air 3000 Compressor:
· Acceptable turbine oil

· Acceptable motor bearing grease
· Acceptable inlet guide vane assembly drive screw 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, of the complete Turbo Air 3000
Compressor Operator’s Manual.
It is the user’s responsibility to provide all lubricants (including turbine 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 3000 Compressor.
Compressor Oil Selection

The correct lubricating oil is critical to satisfactory overall compressor performance. When operating
the Turbo Air 3000 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, Cooper
Turbocompressor 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 Cooper Turbocompressor scientists and engineers to increase performance. In test after
test of standard quality indicators, TurboBlend Lubricating Oil outperforms solvent refined, commer-
cially available oils.
TurboBlend Lubricating Oil is available through your authorized Cooper Turbocompressor representa-
tive or directly from the Cooper Turbocompressor 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—6
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 3000 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 Cooper Turbocompressor Oil Specification
2—7
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 3000 Compressor are not so severe as to require the qualities
of high-cost synthetic oil. In addition, Cooper Turbocompressor 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 Cooper Turbocompressor TurboBlendTM 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.
Cooper Turbocompressor 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 Cooper
Turbocompressor Aftermarket Department. (See Section 8 of this manual for sampling kit part number
information.)
2—8
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 motor. To ensure long life
of the bearings of both motors, it is necessary to maintain both proper alignment and proper lubrica-
tion levels at all times. The large, squirrel cage inductor motor of the Turbo Air 3000 Compressor
employs (depending on the specific type of motor used) either anti-friction bearings or sleeve bearings.
Each type of bearing has different lubrication requirements.
Refer to the motor manufacturer’s instructions provided separately for complete information
regarding correct oil bearing lubrication maintenance procedures for each type of motor.
Anti-Friction Bearings—Grease
For best results with anti-friction bearings, use grease compounded from a non-soap base and a good
grade of petroleum oil. Table 2—2 lists acceptable greases that meet those requirements.
Acceptable Motor Bearing Greases

Chevron Oil SRI #2®
Exxon Unirex N2®
Shell Oil Dolium R®
Texaco Premium RB®
Cooper Turbocompressor does not recommend the products of any individual grease manufacturer.
This listing constitutes neither endorsement of any product nor exclusion of comparable products
not listed.
Table 2—2 Acceptable Motor Bearing Greases
Sleeve Bearings—Oil
It is the user’s responsibility to fill the motor bearing oil reservoir and to maintain the correct oil level at
all times. When lubricating sleeve bearings, use only a high quality, petroleum-based oil with a viscosity
of 200-220 SSU at 100° F (40°C). Since motor bearings require the same type of oil as used in the
compressor itself, it is not necessary to maintain two separate supplies of oil if this type of bearing is
used.
CAUTION:
Before aligning or using this type of motor, always verify that the correct amount of oil is
in the reservoir. Motors with sleeve bearings are sometimes shipped without oil in their
reservoirs.
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.
2—9
Cooper Turbocompressor 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. (Cooper Turbocompressor Coupling Grease is specially formu-
lated to meet this very specific requirement.)
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 Cooper Turbocompressor Coupling
Grease only.
Inlet Guide Vane Assembly Drive Screw Grease

Use a high quality, synthetic grease when lubricating the actuator drive screw. Do not use a
non-synthetic grease for lubrication of this assembly, since such greases tend to thicken during cold
operating conditions. Consequently, they tend to hinder or possibly even prevent proper operation of
the inlet guide vane assembly
Bypass Valve Lubricant

Compressors equipped with AUTO-OFFLINE Control utilize a pop-action bypass valve to vent the
discharge side of the compressor. Two different size and type of valves are employed depending
upon volume flow requirements. The valve supplied with units rated up to 600 horsepower must be
lubricated periodically, while the larger valve for units rated 700 horsepower and larger requires no
lubrication.
The only product Cooper Turbocompressor found acceptable for this service is Dow Corning
MOLYCOAT 33®. Other products may gum up under certain operating conditions and cause the
valve to malfunction.
2—10
The Control System
Section Three
The Control System
¨ The Vantage Control Panel
¨ The Vantage User Interface
¨ Input or Operational Keys
¨ Practice Exercise
3—1
The Turbo Air 3000 Centrifugal Compressor Handbook
3—2
The Control System
The Vantage Control Panel

The major components of the Vantage Controller are mounted in a weatherproof electrical enclosure
with a NEMA 4 rating. One or more Main Logic Modules (MLM) are included in the panel. Each MLM
contains a power supply, a microprocessor, and an I/O (input / output) segment. Depending upon the
particular application, up to two additional slave MLM units may accompany the master MLM to
increase I/O capacity.
Each master MLM also contains the hardware to support a User Interface Module (UIM). The UIM is a
full-page, back-lit liquid crystal LCD display with an integrated 15 key, tactile keypad. The display
provides 20 lines by 80 characters of detailed information on the operational condition and settings of
the controller.
The acceptable operating environment of the control panel includes an operating temperature range
of 32ºF to 140ºF (0ºC to 60ºC), and a maximum 95% relative humidity (non-condensing). The storage
temperature range is -4ºF to 140ºF (-20ºC to 60ºC).
The source power is 100 - 240 VAC, 50 or 60 Hz. A 10-amp fuse protects the MLM circuitry. All wiring,
including grounding, must be in accordance with local codes and the National Electric Code (NEC) in
the USA.
CAUTION:
The MLM is neither designed not intended to supply power to any other device.
Do not wire any other devices from the MLM.
The display, or UIM, receives electrical power from the MLM through the DB9 cable with connectors.
Do not attempt to supply power to the UIM from any other source other than the MLM.
The Vantage Controller operates similarly to a personal computer (PC). Operating system software is
stored in flash memory located in the MLM. The operating system provides a real time, multi-tasking
environment for control programs. Control programs are loaded and saved to flash memory prior to
installation. Once loaded, these programs are maintained in memory by a small battery or saved to flash
memory. It is not necessary to load programs into the Vantage Controller except during certain special
installations, or if a new MLM is installed.
The MLM and UIM contain no user serviceable parts.
Cleaning - If the MLM becomes dirty, use only a dry cloth to clean the part. Never apply water or any
solvent. If the display, or UIM, should become dirty, a mild detergent can be used for cleaning. Use a
soft, non-abrasive cloth to clean the display. Do not submerge any part.
3—3
Audubon Mens Club
The Vantage Control Panel User Interface
Figure 3—1. User Interface Module
1. Display
Presents critical diagnostic and operating information, including startup, shutdown, alarm warnings, trips,
setpoint changes, and much more
2. Index or Menu Keys
Access screens that display information about compressor operation and control parameters, historical data
and networking.
3. Function Keys
Operate the compressor, display and adjust accessible set points.
4. Input or Operational Keys
Allows the operator to navigate through the various screens and to observe and change control parameters by
changing values, manipulate control valves, enter changes to control constraints.
5. EMERGENCY STOP Push Button (not shown)
When pressed, immediately removes all power to the main drive motor. This device should only be used in case
of an emergency. (The Emergency Stop button must be pulled out before starting the compressor.)
3—4
The Control System
Index or Menu Keys

These four keys provide the operator access to numerous screens that display compressor real-time
operational data, along with control, historical and networking information from the Vantage Control
System.
The following descriptions and sample screens demonstrate data from both standard and optional
monitoring instruments that may or may not be included on all models.
Home
Press to display the "Home" screen as selected by the compressor user / owner.
View
This key displays a list of screens that show current compressor values. The compressor
performance settings cannot be changed using this key.
When this key is pressed, the screen below appears and allows the operator to select
any of the screens.
View Pages
Performance Control
Monitor Points
Control Points
Monitoring Chart
Protection (Running)
Protection (Startup)
Startup Status
Efficiency
Information
Auxiliary Control
Turbo DryPak Control
History
Press this key to display records of compressor operation.
The screens available include:
History • Protection History
• Event History
• Operation History
• Motor Trip History
• Set Point History
• Surge Test Results
Network
This displays screens for managing the optional networking feature. When networking
is present on the system these screens include:
• Compressor Network
• Modbus Interface
3—5
Function Keys
Four of these five keys are used to operate the compressor and to have it produce compressed air. The
fifth key allows the operator to adjust certain setpoints that regulate the compressor’s operation.
Some of the following screens demonstrate messages for accessory equipment or instrumentation that
may not be installed on specific units. These screens will, however, alert the reader as to what some of
these options are and how they are applied.
Start
Press this key to initiate the compressor starting sequence. The screen below shows a
typical start sequence. As the Vantage Controller proceeds through the sequence, the
display advances through each step in the sequence. The actual screen on your system
may show other steps.
Compressor Start Sequence
Description Status
1: Opening Water Valve Complete
2: Oil Pressure > 100 psi Complete
3: Oil Temperature > 70 Waiting 1
4: Discharge Pressure < 5 psi
5: Checking Water Flow
6: Motor Enable
7: Starting Compressor
8: Waiting for Motor Speed
9: Compressor Ready to Load
Stop
This key initiates the compressor stop sequence. Screens below are typical of those you
see after pressing Stop. An initial screen tell you the compressor is unloading and the
second goes through the remaining events of the sequence.
Compressor Stop Sequence
Description Status
1: Motor Enable = OFF Completed
2: Oil Pump = OFF Completed
3: Turning Off Water = ON Waiting 3
3—6
The Control System
Auto
This key launches the compressor automatic control mode enabling it to respond
automatically to changes in system demand per a pre-selected control method.
(The control method for your system was determined at the time of order and is
based on the specific application. For information on control strategies and the
methods available, refer to the Control Logic Appendix.)
Unload
This key disables the Auto mode and unloads the compressor by opening the blow off
valve and closing the inlet guide vanes. The system continues to run but does not
respond to changes in air system demand until someone presses the Auto key.
Set Points
Pressing this key displays the lists of set points you can open and change depending on
your level of access. The opening Set Points screen below shows the four access levels.
Set Points
Operator
Maintenance
Service
Configuration
Access levels are password protected at the discretion of the owner. Some set points
are factory set and cannot be changed.
3—7
Input or Operational Keys

These keys allow the operator to communicate with the control system. Using these keys you can
maneuver among the control screens, change alpha-numeric values of set points, and change
the various control constraints or entered using these keys in the manner described below.
You can simultaneously manipulate the throttling and blow-off valves by using the two sets of
paired keys.
Increase and Decrease

Use this pair of keys to perform these operations:
• Raise or lower the value of any numeric or alpha character highlighted on a
particular screen.
• Toggle between two conditions (e.g.: ON/OFF; Alarm/Normal; Yes/No).
• Manually step open or close the inlet valve or inlet guide vanes. (Full manual
control must be authorized to use this function. See: Set Points / Manual
Control / Enter.)
Enter
Press this key to navigate and perform the following operations:
• Select and move into the highlighted field or screen. (e.g.: After navigating to
an item on a menu screen, press Enter to open or expose that subject's screen.)
Enter
• Advance the cursor to the next entry data field or to the next digit within a
data field.
• Confirm changed/displayed values (by moving away from the page).
Back
Press this key to navigate and perform the following operations:
• Return to the previous display screen.
• Move the cursor back within a particular selection screen or data entry field.
• Confirm changed/displayed values (by moving away from the page).
Up
Use this pair of keys to:
• Display additional information within a multi-paged screen. (Relocate "up" or
"down" to the next page.)
• Navigate up or down within a list.
• Manually step open or close a modulating blow-off valve. (Full manual control
must be authorized to use this function. See: Set Points / Manual
Control / Enter.)
• Increase or Decrease the contrast of the LCD display when used in
combination with the View key.
3—8
The Control System
Practice Exercise
You can use this practice exercise to gain familiarity with the various keys and to view representative
screens on the display before the actual startup and operation of the compressor under the Vantage
Control System.
When exploring the display screens with option lists, remember to use the Up and Down keys to move
through the various selections. Press the Enter key to advance to the next screen.
DANGER:
Be absolutely sure that the main motor starter connection has been disconnected and
locked out before attempting this practice exercise. Failure to do so may result in equip-
ment damage, personal injury or death.
Temporary Power Connection

If your system's Vantage control panel is already wired to the main motor starter control power trans-
former, disconnect the power supply directly at the Vantage Controller and reconnect the Vantage
Controller to a separate power source with a temporary power cable.
The source of power is 100-240 VAC, 50 or 60 Hz. Make the power connections at terminal
block J15, on the right side of the Main Logic Module (MLM).
Make the temporary power cable connection as follows:
1. Connect the main power lead to the terminal labeled L1.
2. Connect the neutral lead to L2.
3. Connect the earth ground to GND.
4. Avoid electrical interference problems by keeping the power leads away from the analog
or communication wiring.
Procedure
Some of the sample screens shown here demonstrate data from both standard devices and
optional monitoring devices that may not be included on all models. It should also be noted that
this exercise is intended to familiarize an individual with those features required to operate the
compressor in a safe and efficient manner. Details regarding control system setup,
troubleshooting or maintenance are provided elsewhere.
Proceed with the practice exercise as follows:
1. Plug the temporary power cable into the power source.
2. Make sure that the Emergency Stop button is pulled out.
3. The LCD display should be visible. If the LCD display is difficult to read, try the following to
improve the clarity:
• Unplug the power cable from the electrical receptacle, and then plug the cable back in.
• If the panel is cold, it may take a few minutes for the display to improve.
• To adjust the backlighting further, press and hold the View key while simultaneously
pressing the Up or Down key to increase or decrease the contrast.
3—9
4. Press the Home key to display the “Home” page selected by the compressor owner. Any of
the View screens are practical choices to give the operator quick and easy access to
important operation or protection data. Probably the most popular screen selected is the Perfor-
mance Control Screen (seen below).
Performance Control
Performance Control Screen (Typical "Home" Screen)
5. Press the View key for a list of screens that provide compressor operational information;
press Up or Down to move to Protection (Running),and press the Enter key to display the
Protection (Running) screen (below).
Trip Alarm Alarm Trip
Description Tag Low Low Data High High
1: System Air Pressure PT-100 70.0 98.2 110.0 110.0
rd
2: 3 Stage Discharge Press PT-106 101.1 130.0 135.0
3: Drive Motor Current IT-199 148 165 173
4: Oil Pressure PT-159 70.0 80.0 110.0 140.0
5: Oil Temperature TE-147 60.0 70.0 110 140 150
st
6: 1 Stage Vibration VT-192 0.23 1.50 2.00
nd
7: 2 Stage Vibration VT-194 0.14 1.50 2.00
8: 3rd Stage Vibration VT-196 0.17 1.50 2.00
9: Inlet Air Filter DPT-107 4.2 8.0 10.0
10: Motor Power JT-199 1014
11: Motor Stator A Temp TE-199A 112 150 165
The Protection (Running) screen shows the monitored points that protect the compressor the
instrumentation identification numbers (Tag). The Data column shows the current value of each
point, plus the Alarm and Trip set points of each attribute. Values shown are in units as defined.
3—10
The Control System
6. Press Back (or View) to return to the View page.
7. Press Up or Down to move the highlight to Startup Status and press Enter to open the screen.
The Startup Status screen (sample screen below) is active only when the compressor is stopped. The
elements displayed, along with a status indication, are those necessary for a permissive start. Each
condition must show a "Ready" status before a successful start.
Startup Status
Description Status
rd
2: 3 Stage Discharge Pressure < 3.0 Not Ready
3: Oil Temperature > 70 Ready
4: Oil Pressure > 80.0 Not Ready
Other index keys access to additional history and networking information, not essential to the safe
and efficient operation of the compressor. This practice exercise is only to help develop your confi-
dence in the basic navigation and operation of the Vantage controller.
8. Press the Set Points key to display a list of set point selections.
Press the Up or Down key as needed to highlight the Operator access level.
Press the Enter key to open the screen. (In this example, the System Pressure is set at 98.0 psi.)
Operator
System Pressure Setpoint: 0 0 9 8.0

System Pressure Offset: 3.0
Maximum Motor Load (%): 100.0
For this exercise, raise the System Pressure Set Point from 98 psi to 103 psi in the following
manner:
• Press Enter to move the cursor to the hundreds column.
• Press Increase to change the value in this column to 1.
• Press Enter to acknowledge the new value, and to move to the next column.
• Press Increase to change the value in the tens column to 0.
• Press Enter to acknowledge, and to move to the units column.
• Press Increase or Decrease repeatedly until a value of 3 appears.
• Press Enter.
• Press Enter again to confirm the new set point, and to return to the Set Points
selection screen.
9. Learn about other screens or panel functions by using the Input or Operational Keys as demon-
strated in Step #8. Some set point values are critical to the protection of the compressor and
cannot be changed by the operator.
10. When complete, unplug the temporary cable from the power source and restore the original panel
power connection. (A qualified electrician may be required to make this connection.)
3—11
3—12
Routine Operation
Section Four
Routine Operation
¨ General Considerations
¨ The Operating Data Record
¨ Routine Startup — LOCAL Control
¨ Routine Shutdown — LOCAL Control
¨ Adjusting the Pressure Setpoint
4—1
4—2
Routine Operation
General Considerations
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.)
Although it may be necessary to review and adjust setpoints to reflect changes in operating conditions,
little other attention is required other than that described in Section Five. However, in addition to
operator inspection and attention at periodic intervals.
To assure long life and optimal output from the Turbo Air 3000 Centrifugal Compressor, always follow
the prescribed maintenance procedures. If problems arise, contact a Cooper Turbocompressor factory
trained and authorized service representative for technical assistance.
WARNING:
When in the process of starting or stopping compressor operation under routine
conditions, do not attempt to restart the compressor until operation has stopped
completely. Restarting the compressor before full shutdown will cause equipment
damage.
The Operating Data Record

Cooper Turbocompressor recommends keeping an Operating Data Record to list inspections and to
store operating data for trend analysis. This record should contain the checklist items included in Table
4—1, along with spaces for the operator’s initials and the time and/or date to ensure that each item or
procedure receives the recommended periodic attention. Keep in mind, however, that Table 4 actually
includes a wide range of options, and remember that not all options are included on all units. (Users
may wish to mark those options that are included in any particular installation for easy reference.
However, if other options are added at a later time, be sure to update the list.)
The Operating Data Record is included as part of the Daily Inspection Checklist contained in Section
Five, Maintenance.
4—3
Operating Data Record

Pressure
Ö Discharge Air Pressure:
Ö System Air Pressure:
Ö Main Oil Pressure:
Ö * Inlet Air Filter Drop:
Ö * Oil Filter Pressure Drop:
Temperature
Ö Oil Temperature:
Ö * Stage 2 Inlet Temperature:
Ö Stage 3 Inlet Temperature:
Ö * Discharge Air Temperature:
Ö * Motor Stator 1 Temperature:
Ö * Motor Bearing Temperature Drive End:
Ö * Motor Bearing Temperature Non-drive End:
Vibration
Ö Stage 1 Vibration:
Ö * Stage 2 Vibration:
Ö * Stage 3 Vibration:
Ö * Motor Vibration at Drive End:
Ö * Motor Vibration at Non-drive End:
Power
Ö Motor Current:
Time
Ö Date:
Ö Time:
Ö Total Running Time:
Ö Current Running Time:
* These are optional sensors which may not be included on all models.
Table 4—1 The Operating Data Record
4—4
Routine Operation
Routine Startup—Local Control

Use this procedure to start the compressor locally from the User Interface Module (UIM).
WARNING
Only fully trained personnel should be allowed to start and operate this compressor.
Failure to comply may result in serious injury or death.
1. Close the condensate drain bypass valves.
2. Turn on the cooling water supply. (May occur automatically as part of start sequence.)
3. Check the oil level in the oil reservoir.
4. Activate the oil reservoir vent system (air-powered ejector, or electric-powered vacuum pump),
and adjust appropriately.
5. Rack in the main drive motor starter disconnect.
6. Inspect the compressor for any water or oil leaks.
7. Open the discharge air system block valve. (May occur automatically as part of start sequence.)
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 START key on the Vantage Control Panel and observe the compressor start sequence.
A screen appears similar to the screen shown below.
Starting
Description Status
1. Oil Pressure > 100.0 PSI Complete

2. Oil Temperature > 70 Waiting 2
3. Discharge Pressure < 5 PSI
4. Checking Water Flow = ON
5. Motor Enable = ON
6. Start Signal = 8.00
(This is sample screen that may contain extra messages.)
9. After startup, control defaults to the Auto mode. Press Home to observe selected processes
and verify stability. To stop the Auto mode, press Unload.
4—5
Routine Shutdown—Local Control

Use the following procedure to shutdown the compressor under normal conditions.
CAUTION:
If the compressor is to be shutdown for an extended period in a cold environment, drain
all water from the compressor's cooling system after the shutdown. Water in the heat
exchangers may freeze and cause damage to the internal tubes. An alternative to draining
is to maintain some minimum flow through the coolers.
1. Press the STOP key.

The automated stop sequence, including stopping the motor, begins.
Stopping
Description Status
1. Motor Enable = OFF Completed

2. Oil Pump = OFF Waiting 2
(Note: Messages and data displayed on stop sequence screen may differ among systems.)
2. When you press the STOP key, the Vantage control system software tells the bypass valve (or
blow-off valve) to open and the inlet guide vanes (or other throttling device) to close
completely. (This takes 10-15 seconds.) In addition to the closing of the inlet, the
automated stop sequence begins.
3. Close the air system block valve.*
4. Open the condensate drain bypass valves. (May occur automatically as part of sequence.)*
5. Allow the cooling water and oil to circulate for at least 30 minutes to remove heat.
6. Turn off the water supply, if not controlled automatically. (May occur automatically as part of
sequence.)
7. Stop the electric oil pump, if wired separately. (May occur automatically as part of sequence.)
8. Rack out the drive motor starter disconnect.
9. Turn off the reservoir venting system.
4—6
Routine Operation
Adjusting the System Pressure Set Point

During normal operation, it may become necessary to make small adjustments to the System
Pressure Set Point in order to alter the operating characteristic of the compressor. The example here
shows a System Pressure that has been set at 98.0 psi.
CAUTION:
DO NOT operate the compressor at pressures greater than the nameplate rating.
Doing so could result in equipment damage or personal injury.
Adjust the System Pressure Set Point as follows:
1. Press the Set Points key to display a list of set point selections.
2. Press the Up or Down key as needed to highlight Operator .
3. Press the Enter key to open the Operator screen. (Enter your Operator Access Code if
prompted)
Pressure Setpoint
System Pressure Setpoint: 0 0 9 8.0

System Pressure Offset: 3.0
Maximum Motor Load (%): 100.0
Use Enter key

to move cursor
to the right
4. Use the Up or Down key to move the cursor to the value you want to change.
5. Press Enter to move the cursor right to the digit you want to change.
6. Press the Increase or Decrease key to change the value of that digit.
7. Press Enter to move to continue moving through each digit, changing the value of digits
only where necessary. (Back moves the cursor to the left.)
8. On completion press Enter to return to the Set Points selection screen.
4—7
4—8
Maintenance
Section Five
Maintenance
¨ Daily Inspection
¨ Scheduled Maintenance
¨ Professional Inspection
¨ Filter Maintenance
Inlet Air Filter
Bypass Valve Filter
Oil Reservoir Vent Filter
Standard Oil Filter
Duplex Oil Filter
¨ Lubrication
Compressor Lubricating Oil
Oil Pump Motor Bearings
Main Drive Coupling
Drive Motor Ball Bearings
Inlet Guide Vane Drive Screw
Bypass Valve
¨ Additional Maintenance
Heat Exchangers
Intercooler Cleaning
Oil Cooler Cleaning
Accumulator Testing
Discharge Air Check Valve
Inspection
5—1
5—2
Maintenance
The Turbo Air 3000 Centrifugal Compressor requires minimal maintenance. However, monitoring
operating conditions on a daily (or shift change) basis is good practice. It allows the operators to
become familiar with a smooth running machine which will lead to early detection of potential prob-
lems. The result is improved overall performance, a dependable supply of compressed air, longer
compressor life, and lower overall compressed air costs.
Just as with any other type of machinery, compressors are subject to operational changes from environ-
mental conditions, wear, or neglect. A plugged condensate drain, unusual noises, temperature or
vibration increases, discolored oil, and/or fluid leaks are some examples of operational changes that
may signal beginning of potential problems. Recognizing any changes in operation and appropriately
responding to those changes can prevent undesirable consequences such as unscheduled shutdown
and/or 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
3000 Centrifugal Compressor is a high technology product, for all other procedures always
consult a Cooper Turbocompressor trained and authorized service representative.
5—3
Daily Inspection
A daily inspection takes only a short time, but it will allow the operator to develop a definite sense of
the appearance, sounds, and other operating conditions of a smoothly performing compressor. Any
changes can be investigated and be given attention before major problems develop. Table 5 – 1 lists
the items that should be monitored daily (or with a shift change).
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 recorded
Gearcase (High surface temperatures)
3 External surfaces wiped clean
3 No unusual noise or vibrations
3 No oil leaks
3 No water leaks
3 No frayed or worn electrical cables
Intercoolers and Aftercooler (Pressurized air, high surface temperatures)
3 Condensate drains functioning properly
3 No cooling water leaks
3 No air leaks
Lubrication System (High voltages at heater, pump motor)
3 Proper oil level in oil reservoir
3 Proper oil color
3 No mist from ejector system
3 No oil cooler water leaks
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 suggested intervals for prescribed scheduled maintenance procedures such as those
involving filters, lubrication, and other inspections and/or adjustments. Bear in mind, however, that
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.
Scheduled Maintenance Procedures

When servicing the Turbo Air 3000 Centrifugal Compressor, use only genuine Joy® and Cooper
Turbocompressor replacement parts and recommended supplies available through Cooper
Turbocompressor and/or authorized representatives.
Weekly:
(or after about 150 hours of operation)
3 Inlet air filter elements inspected, replaced if required

3 Oil reservoir venting system filter elements inspected, replaced if required
3 Bypass valve filter checked (if supplied)
Every Six Months:

(or after about 4000 hours of operation)
3 Oil reservoir venting system filter element changed

3 Oil system filter element changed
3 Lubrication system oil tested and changed if required
3 Coolant chemically tested
3 Bypass valve lubricated (if required – check instructions)
3 Inlet guide vane assembly drive screw lubricated
3 Main drive coupling inspected and lubricated.
3 Drive motor ball bearings lubricated with recommended grease. *
3 Oil pump motor lubricated with recommended grease
3 Discharge air check valve inspected
*Refer to the motor instructions for specific interval guidelines.
Table 5—2 Scheduled Maintenance Procedures
5—5
Professional Inspection
A substantial part of any good preventative maintenance program also involves professional inspection
and replacement of common maintenance components after an established interval. Such in-depth
inspection is particularly important when an unscheduled and/or long-term shutdown would seriously
affect production. Table 5—3 lists the items which require a professional service inspection whenever
environmental or operational conditions dictate. Contact a Cooper Turbocompressor trained and
authorized service representative for those procedures and for professional advice.
Service Inspection Checklist

To be performed with a Cooper Turbocompressor authorized representative:
Gearcase*
3 Impellers, inlets, and diffusers cleaned
3 Impellers, inlets, and diffusers inspected
3 Gearing visually checked
3 Gearing backlash clearances measured
3 Axial pinion float checked
3 Clearances between impellers and inlets checked
Intercoolers* and Aftercooler*
3 Bundle tubes inspected, cleaned if required
3 Bundle fins inspected, cleaned if required
3 Cooler cavities cleaned and inspected
Lubrication System*
3 Piping connections checked for leaks
3 Oil visually inspected
3 Oil cooler inspected
Filters
3 All filter elements inspected
Control Panel
3 Inspected for proper operation
Control Valves
3 Inlet Guide Vane inspected
3 Bypass valve inspected
3 Discharge air check valve inspected
Drive Motor
3 Main drive coupling inspected and re-greased
3 Motor inspected in accordance with manufacturer’s instructions
*Replacement parts required. Use only genuine JOY® and Cooper Turbocompressor parts and
supplies available through the Cooper Turbocompressor and/or authorized representatives. (Refer to
Section Seven, Parts and Service, for additional information regarding inspection kits.)
Table 5—3 Service Inspection Checklist
5—6
Maintenance
Filter Maintenance
Several filters located in different parts of the compressor system ensure that the air and oil passing
through the system are always clean. For optimum performance the operator must regularly monitor
the condition of these filters, and clean or change filters as required.
Table 5—4 lists the various filters along with recommended inspection intervals and recommended
responses 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* Weekly When dirty or after 12 months
Bypass valve filter* Weekly When dirty or after 12 months
Oil reservoir venting system* Weekly 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 JOY® and Cooper Turbocompressor products. Refer
to Section Seven, Parts and Service, for more information on parts availability through the Cooper
Turbocompressor Parts and Service Department and/or authorized representatives.
Table 5—4 Filter Maintenance Schedule
Inlet Air Filter Cleaning and Replacement

The inlet air filter is a two-stage unit. While the primary filter may be cleaned, the secondary filter
element must be replaced when it becomes dirty and no longer functions properly.
Since compressor operation without the action of the primary filter will contaminate the second-
ary filter very rapidly, Cooper Turbocompressor recommends that user’s stock a spare primary
filter for use as required. It is also necessary to keep a supply of secondary filters for use as
required, since the secondary filter cannot be cleaned and must always be replaced when it
becomes dirty and no longer functions properly.
Because contamination levels vary in different operating environments, the only reliable method to
determine whether either cleaning or replacement is necessary is by measuring the pressure drop
across the filter elements. Use this procedure:
1. Install a differential pressure gauge in either the inlet filter housing or the inlet pipe.
2. Measure and record the current pressure drop. Compare that with the one initially taken when the
new filter elements were installed.
· If the current pressure drop is within 4” (or 100 mm) water column (WC) of the original
reading, continue operation.
· If the pressure drop exceeds the original reading by more than 4” (or 100 mm) WC, that
is an indication that the filters require maintenance.
5—7
3. When necessary, it is possible to clean the primary filter (which has the screen across its face) in
either of these two ways:
· Blow 30 psi (2kg/cm2 or bar) of air from the clean side.

— or —
· Soak and periodically agitate the filter in hot water containing a non-volatile cleaning
agent and then air dry the filter completely before installation.
4. If after cleaning or replacing the primary air filter the air pressure drop returns to normal, that is
an indication that the secondary filters are still clean. However, if the air pressure drop remains
high with the clean or replacement primary filter, it is time to replace the secondary filters.
CAUTION:
Do not operate the compressor for more than 2 minutes without the primary filter. Opera-
tion without proper filtration may cause compressor damage or malfunction.
Bypass Valve Filter Element Replacement

On compressors so equipped, a filter is located in the pilot supply line to the bypass valve. It serves to
prevent water and/or other contaminants from entering the bypass valve’s control mechanism. Use a
Cooper Turbocompressor replacement filter only.
The replacement procedure is as follows:
1. Completely shut down the compressor and exhaust any pressure in the bypass valve air supply line
and filter.
2. Unscrew the canister that houses the filter from the base.
3. Remove the retaining nut that holds the filter element in place.
4. Inspect the canister o-ring seal; if damaged, replace it at this time.
5. Install the replacement filter element.
6. Replace the retaining nut (being careful not to over-tighten it) and then screw on the filter canis-
ter.
5—8
Maintenance
Oil Reservoir Vent Filter Element Replacement

The oil reservoir is vented through an ejector-filter system that does not require frequent maintenance
if its supply air is clean and dry, or if the humidity in the surrounding environment is not excessively
high. Moisture will collect in the filter element and eventually drain back into the reservoir contaminat-
ing the lubricating oil. Use a Cooper Turbocompressor replacement filter only.
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 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 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. If neces-
sary, replace the seals to prevent leaks.
7. Wipe the housing clean.
8. Reassemble the filter and then pour a small amount of oil into the fill connection provided at the
top of the trap line to reinstate the mist filter trap.
Standard Oil Filter Element Replacement

The compressor must be shutdown before servicing the oil filter. When required, use the following
procedure to replace the standard oil filter element. Use a Cooper Turbocompressor replacement
filter only. Filters that look the same may not necessarily perform the same.
WARNING:
Do not attempt to remove the oil filter until oil pressure is at zero (O). Hot oil under
pressure presents a safety hazard to personnel.
1. Shutdown and lock-out the compressor.
2. Shut off the oil pump.
5—9
3. Remove the oil filter, which is of the spin-off variety.
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. Wipe the new filter clean and, after the oil pump has started, inspect for possible leaks.
8. Dispose of the used oil and old filter according to plant procedures.
Duplex Oil Filter Element Replacement

The Duplex Oil Filter option allows for oil filter replacement without the necessity of shutting down the
compressor in order to perform this routine maintenance task. Separate file chambers are incorporated
with a transfer valve. When required, replace the duplex oil filter elements as follows:
WARNING:
Before servicing, be sure the chamber being serviced is not being utilized. Do not attempt
to remove the oil filter element until the oil pressure in that chamber is 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).
3. Inspect the new filter and then, using clean oil, lightly lubricate the gasket.
CAUTION:
Use a Cooper Turbocompressor replacement filter only. This will ensure safe and reliable
performance.
4. Unscrew the filter bowl, and remove the old filter element.
5. Install the new filter element and replace the filter bowl.
6. Depress the balance valve lever until oil begins to bleed through the bleed screw.
7. Turn the bleed screw clockwise until tight. Depress the balance valve lever once more to pressurize
the filter bowl.
8. Dispose of the used oil and old filter according to plant procedures.
5—10
Maintenance
Lubrication
Table 5—5 lists recommended intervals and the products necessary for proper lubrication of various
Turbo Air 3000 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. Cooper Turbocompressor
Change only as required. TurboBlendTM Lubricating Oil
Oil pump motor bearings Six months Table 2—2
Main drive coupling Six months Cooper Turbocompressor
Coupling Grease
Drive motor ball bearings [B] Table 2—2
Drive motor sleeve bearings [B] Cooper Turbocompressor
TurboBlendTM Lubricating Oil
Inlet guide vane actuator drive screw Six months High quality synthetic grease
Bypass valve (if applicable) Six months Molycoat® 33
Notes:
[A] Use only oils and greases recommended by Cooper Turbocompressor
[B] Refer to the motor manufacturer’s instructions for specific interval guidelines.
Table 5—5 Compressor Lubrication Schedule
Compressor Lubricating Oil

Cooper Turbocompressor cannot specify a fixed interval between lubrication system oil changes because
of the wide variety of operating conditions that exist. Therefore, the operator should inspect the oil
visually daily to monitor changes and/or possible deterioration. Compare the appearance of oil from the
reservoir with new oil, and watch for changes in the appearance of the oil as follows:
· If the oil appears darker than normal, that is an indication that there is probably some
contamination.
· If the oil appears muddy or contains any white emulsion, that is an indication that there is
some contamination with water.
As the situation requires, have the oil tested for viscosity, acid, water and other contamination. A
reputable commercial laboratory can easily detect the presence of any such contamination,
Whenever the performance of the lubricating oil is suspect, Cooper Turbocompressor recommends
additional 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.
5—11
Follow the recommendations of the testing laboratory with regard to changing the oil in the
reservoir. Be certain to use only Cooper Turbocompressor TurboBlendTM Lubricating Oil for
optimum performance.
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. Table 2-2 offers acceptable motor bearing greases.
It is not necessary to lubricate the oil pump coupling.
Main Drive Coupling Lubrication

It is necessary to lubricate the main drive coupling every 6 months to meet the manufacturer’s
specifications. (For additional information on lubricant requirements, refer to Section Two,
Compressor Specifications.)
WARNING:
Before performing this procedure, be certain to lock out the main power supply and close
the air system block valve. Failure to follow this requirement may cause serious injury.
1. Stop the compressor. Lock out the main motor starter.
2. Remove the coupling guard.
3. Note that each coupling hub sleeve has two separate lubrication plugs; remove both plugs and,
using a stiff wire brush, clean each one thoroughly.
Insert a grease fitting into each sleeve, and then pump approximately 2 oz. (60 cc) of Cooper
Turbocompressor Coupling Grease into one of the holes in each sleeve until fresh grease flows
from the opposite hole.
WARNING:
Use Cooper Turbocompressor Coupling Grease only. Other greases do not provide
adequate protection.
5—12
Maintenance
4. Move the coupling center spool back and forth to verify free movement. (Total travel should be
0.160” or 4 mm.)
5. Remove the grease fittings, and then replace all plugs.
6. If the center spool does not move freely, correct the interference as follows:
· Remove the center spool.
· Disassemble the sleeves.
· Clean any grease from the gearhubs and sleeves.
· Inspect gearhub teeth for wear; if required, replace the gearhubs and sleeves.
· Re-grease and reinstall the spool.
· Verify that the spool moves freely, and then reinstall the grease plugs.
7. Replace the coupling guard.
Drive Motor Ball Bearings Lubrication

The Turbo Air 3000 Compressor may be equipped with a squirrel-cage induction motor with ball
bearings. The ball bearing grease must be changed in accordance with the motor manufacturer’s
recommendations.
CAUTION:
Do not use excessive amounts of grease. Over-greasing may cause bearing and/or
motor failure.
5—13
Inlet Guide Vane Assembly Drive Screw Lubrication

The inlet guide vane assembly drive screw requires lubrication about every 6 months or as required. Be
sure to use only recommended high quality, synthetic grease when performing this procedure. (Refer to
Section Two, Compressor Specifications, for complete information about lubricants.)
1. Unscrew the cover tube at the motor bracket.
2. Carefully pull away the cover tube, just enough to expose the drive screw.
3. Using a clean cloth, wipe off all the old grease from the drive screw surface.
4. Work fresh grease into the drive screw by hand, being sure to use sufficient grease to cover all
surfaces thoroughly.
WARNING:
Use only the recommended high quality, synthetic grease for this procedure. Under
certain conditions, other products may contribute to mechanism malfunction.
5. After greasing is complete, replace the cover tube and screw it back to the original position.
Bypass Valve Lubrication (if applicable)

Some TA 3000 compressors utilize two different types of bypass valves, depending on the rating of the
compressor. To correctly determine the type of valve used in a particular installation, refer to Figures 5—
1 and 5—2, which illustrate the two types of valves.
Turbo Air 3000 Compressors rated up to and including 600 horsepower utilize a box-shaped bypass
valve which requires periodic lubrication. The larger cylindrical, angled valve employed on higher rated
machines (700 horsepower and larger) does not require lubrication. Both of these valves characteristi-
cally operate either in a fully opened or fully closed position. Every 6 months (or as required), it is
necessary to lubricate the piston’s seals and guide rings of the smaller, box-shaped valve. Since other
products do not provide the required level of protection and could gum up under service, use only the
recommended lubricant. (Refer to Section 2, Specifications, and Section 7, Parts and Service, for full
ordering information.)
5—14
Maintenance
Seal ebuildı
Kit it`
Seal Kit
Lubricant
Figure 5—1 Bypass Valve Figure 5—2 Bypass Valve
WARNING:
Before attempting this procedure, be certain to shut down the compressor, lock out the
main power supply, and fully close the discharge block valve. Failure to follow these
requirements could cause severe injury from pressurized air.
1. Completely shut down the compressor, lock out the motor starter and close the discharge block
valve. Exhaust all line pressures and disconnect the instrument line at the metering valve.
2. Remove the four bolts that hold the solenoid assembly and adapter to the bottom side of the
bypass valve.
3. Remove the top plate to expose the spring and stem assembly and, using the stem assembly, push
out the piston.
5—15
4. Clean all parts of the piston, and carefully inspect the piston bore and piston seals for wear and/or
damage.
WARNING:
If the bore appears damaged, do not attempt to rebuild the assembly. It will be necessary
to replace the bypass valve at this time.
5. If any seals or o-rings appear damaged, replace them at this time.
6. If the piston bore appears to be in good condition (or after a replacement has been made as
required), lightly lubricate the piston bore and the seals on the piston assembly with the recom-
mended grease.
CAUTION:
Use only the recommended lubricant for this procedure. Other products may contribute to
mechanism malfunction under certain operating conditions.
7. When lubrication is complete, reassemble the valve and reconnect the air and electrical supply lines.
5—16
Maintenance
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. The necessity is determined by particular
performance indicators or is performed on a periodic basis. Table 5—6 lists these procedures.
Instructions for each follow.
Other Maintenance Procedures

Procedure: When Required:
Intercoolers/aftercooler cleaning* With elevated interstage air temperatures
Oil cooler cleaning* With intercooler service — or —
With elevated oil temperature
Discharge air check valve inspection At 6 month intervals
*Indicated procedures require the use of commercial products available through the Cooper
Turbocompressor Parts and Service Department. Refer to the specific procedures and Section Seven,
Parts and Service, for more information about these products.
Table 5—6 Other Maintenance Procedures
Heat Exchangers
A decrease in heat exchanger performance is an indication that it may be necessary to clean the inter-
coolers, aftercooler and/or the oil cooler.
The best indicator of the performance level of the intercoolers and aftercooler is the approach tempera-
ture. This is defined as the difference between the temperature of the air leaving the heat exchanger
and that of the water entering the heat exchanger. Record that information for all heat exchangers
when the compressor is first installed and running at full load. When an approach temperature in-
creases by 15°F - 20°F (8°C - 11°C) above the original level, or when an Alarm condition occurs as a
result of high interstage temperature, that is an indication that it is time for cleaning.
In the case of the oil cooler, however, the approach temperature cannot be used to determine a de-
crease 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 water flow.

· Be sure that the oil and air resistive temperature detectors (RTD’s) are functioning properly.
· Be sure that the condensate drains are functioning properly.
When it becomes apparent that cleaning is necessary, keep in mind that separate techniques are
utilized for different parts of the heat exchangers:
5—17
· Tubes The tubes must be cleaned using a series of brushes (in the case of the intercoolers and
aftercooler) or a rod (in the case of the oil cooler) and then given a thorough soaking with a
commercial descaling agent such as RydlymeÒ.
· Fins The aluminum fins of the intercoolers and aftercooler must be cleaned using a high pressure
air, steam, or water spray and then given an additional soaking with a commercial cleaning agent
such as Coil BoilÒ.
Instructions for cleaning both the water and air sides of the intercoolers and aftercooler are included
here, along with instructions for cleaning the oil cooler.
Refer to Section Seven, Parts and Service, for complete information about ordering specified commer-
cial products required for this procedure.
Intercoolers and Aftercooler Cleaning

Water Side:
Use a gun-cleaning or tube-cleaning kit for this procedure. Such commercially available kits come with
a selection of brushes in varying sizes, making them ideally suited for this purpose. The recommended
range of brush sizes is from 1/4” to 3/8” (6 to 10 mm), to allow the user to begin cleaning with a
smaller size brush and then progress to the largest size.
1. Shut down the compressor and exhaust all air pressure. Lockout the main motor starter and close
the system block valve.
2. Shut off the cooling water and remove the supply piping.
3. Drain the coolant, and then remove the intercooler headers.
4. Remove the intercoolers from the cooler cavity. (Refer to Figure 5—3.)
5. Inspect the cooler casings for corrosion. If necessary, clean the casings.
5—18
Maintenance
Front Tubesheet Gasket
Y-Gasket
K-Seal
Upper Baffle Plate
Intercooler Bundle
Header Gasket
Figure 5—3 Intercooler Disassembly

Water Cooler
1. Remove all loose scale from the interiors of the cooler cavity, the water headers, and the manifold
pipes.
CAUTION:
Do not allow the loose debris to enter the condensate drain lines. This could cause
plugging of the drains.
2. Using a 1/8” (3 mm) rod, probe the length of the intercooler tubes to check for any blockage.
5—19
CAUTION:
If the compressor is equipped with U-bend water tubes, do not force the rod into the U-
bend. Doing so could cause damage to the tubes.
3. Stand the bundles with the tube openings up, and fill the tubes with commercial descaling agent
such as Rydlyme.
WARNING:
Be sure to follow the manufacturer’s instructions for safe handling and disposal of such
products. Failure to do so could cause personal injury and/or create a biohazard.
4. Allow the tubes to stand for 2 hours with the descaling agent inside; then completely drain the
descaling agent from the tubes and flush them thoroughly with water.
WARNING:
Do not leave the descaling agent in the tubes for more than 2 hours, and do not allow the
descaling agent to make contact with the intercooler fins. Failure to follow these instruc-
tions will cause component damage.
5. Allow the descaling agent to completely drain from the tubes, and then flush the tubes thoroughly
with water.
6. Attach a 1/4” (6 mm) diameter soft bristle brush (nylon or brass) to a 20” (500 mm) long rod. Then
connect that assembly to a drill motor.
7. Use the drill motor to power the rod/brush assembly in and out of the tubes, which should be
constantly flushed with water. (The flushing is necessary to clear loose debris through the tubes.)
CAUTION:
If the compressor is equipped with U-bend water tubes, do not force the rod into the U-
bend. Forcing could cause damage to the tubes.
8. Repeat the previous step with the next larger brush size, progressing (using the same procedure
with each brush) until the largest size is reached.
9. When the brush cleaning is complete, drain all the water from the tubes and then fill them to the
top with a descaling agent. Allow the descaling agent to remain in the tubes for 1 hour.
CAUTION:
Do not leave the descaling agent in the tubes for more than 1 hour, and do not allow the
descaling agent to make contact with the intercooler fins. Failure to follow these instruc-
tions will cause component damage.
5—20
Maintenance
10. Drain the descaling agent and thoroughly flush the tubes with clean water.
11. Again using the drill motor and the rod/brush assembly, brush in and out of the tubes using the
largest brush (3/8” or 10 mm) while simultaneously flushing out the tubes with clean water.
12. If necessary, clean the air side of the heat exchanger. (Refer to the following procedure for com-
plete instructions.)
13. When the cleaning is complete, immediately reinstall the intercoolers. (If they are not reinstalled
immediately, it will be necessary to repeat Step 15 before they can be reinstalled.) Clean all gasket
and seal surfaces, reassemble the unit using all new gaskets and seals, and then reposition it in the
cooler cavity of the compressor.
Intercoolers and Aftercooler Cleaning

Air Side:
It may also be necessary to clean airborne contaminants from the air side of the coolers. To clean the
intercooler fins on the air side, use compressed air, pressurized water, or steam. Loosen any dirt or
debris as follows:
WARNING:
Always wear eye protection and protective clothing and observe proper safety precautions
when using compressed air or steam. Failure to heed this requirement may cause personal
injury.
1. Remove the upper and lower baffle plates to expose the complete finned surface.
2. Clean the fins by passing a 30 psi (2 kg/cm2 or bar) air stream across them.
— or —
If air is not available, it is possible to use a low-pressure steam or water spray to clean the fins.
3. If necessary, clean any contaminant buildup from the aluminum fins by using a chemical cleaning
agent such as Coil Boil.
WARNING:
Be sure to follow the manufacturer’s instructions for safe handling and disposal of the
chemical cleaning product. Failure to follow proper safety procedures may cause personal
injury and/or create a biohazard.
4. If any bent fins are visible after the cleaning procedure, carefully straighten them out by hand
before replacing the baffle plates.
5—21
Oil Cooler Cleaning

Deterioration in oil cooler performance may be an indication that it is time to remove the mineral scale
buildup within the oil cooler tubes. When that occurs, clean the tubes as follows:
1. Shut down the compressor, lockout the main motor starter and close the system block valve.
2. Turn off the water and disconnect the two water pipes.
3. Remove the lower plug on the rear header and allow any remaining coolant to drain from the
cooler before replacing the plug.
4. Remove the front and rear headers to expose the tubes. Retain the gaskets.
5. Using a 1/8” (3 mm) rod, probe the tubes to check for blockage. (Since this is a straight tube cooler,
any blockages that are loosened can be safely and easily pushed through and out the end.)
6. When rod cleaning is complete, flush the tubes thoroughly with water.
7. Replace the water headers (using the original gaskets) and then fill all the cooler tubes with a
descaling agent such as Rydlyme.
WARNING: Be certain to follow the manufacturer’s instructions for safe handling and
disposal of such products. Failure to do so could cause personal injury and/or create a
biohazard.
8. Allow the descaling agent to remain in the tubes for 1 hour.
CAUTION:
Do not allow the descaling agent to remain in the tubes for more than 1 hour. Failure to
follow these instructions will cause component damage.
9. Remove the front and rear headers to again expose the tubes.
10. Allow the descaling agent to completely drain from the tubes, and then flush out the tubes thor-
oughly with water.
11. Reassemble the headers, this time using new replacement gaskets.
12. Recharge the cooler, being sure to loosen the vent plug on the rear header to prevent air entrap-
ment in the cooler.
5—22
Maintenance
Discharge Air Check Valve Inspection

At 6 month intervals, use the following procedure to inspect the discharge air check valve to determine
whether it is still in good working order or whether it must be replaced.
1. Shut down the compressor and lockout the main motor starter.
2. Close the system block valve and exhaust any pressure in the check valve line.
3. Remove the check valve from the piping.
4. Remove both plugs and the hinge pin, and then inspect the hinge pin, disc, and seat for wear.
5. If any parts are worn or damaged, replace the valve.

— or —
If wear is not apparent, clean, reassemble, and reinstall the valve, being sure that the valve disc
operates freely.
6. To verify correct orientation of the discharge air check valve, use the following criteria:
· The check valve should be located downstream of the blow-off valve and upstream of the
system block valve.
· The arrow should be pointing in the direction of flow (away from the compressor).
· For horizontal installation (the recommended position) the hinge pin must be above the
centerline, which is assured when the metal label can be seen from the top of the valve.
WARNING:
When installing a new discharge check valve or reinstalling a valve, always be certain of
proper orientation. Incorrect orientation will cause equipment damage.
5—23
5—24
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 3000 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 Vantage 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 Cooper
Turbocompressor 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
Cooper Turbocompressor 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 Cooper Turbocompressor factory trained and
authorized service representative. The Turbo Air 3000 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

Cooper Turbocompressor 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 Cooper Turbocompressor
trained and authorized service representative and only genuine Cooper Turbocompressor
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 Cooper Turbocompressor sales and
service representative. Refer to Section 7, 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 Vantage 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 Vantage 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. Press the Home, View, History, or Network key to 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. Press the View key and use the Up or Down keys to select the Protection (Running) screen.
4. Press the Enter to open the screen. Review the current monitoring point information and its
relationship to the Alarm and Trip set points.
5. 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.
Example
The next sample screen shows a representative Alarm message, in this instance signaling abnormal oil
pressure.
Operator Response
With the Protection History screen being displayed on the control panel, the operator should:
1. Take note of the actual oil pressure as displayed under the Data column.
2. Press the View key and use the Up or Down keys to select the Protection (Running) screen.
6—6
Troubleshooting
3. Press the Enter key and compare the current operating oil pressure from the previous Protection
History screen to the Alarm and Trip set points.
Protection History
# Date Time Type Description Tag Data

001 09-01-01 20:43:25 Alarm Low Oil Pressure PT-159A 79.8
002 08-24-01 16:58:15 Trip High Oil Temperature TE-147 151
003 08-20-01 05:10:40 Alarm High Oil Temperature TE-147 143
004 08-08-01 10:10:05 Alarm High Oil Temperature TE-147 144
005 07-28-01 17:21:44 Alarm High Water Flow
006 07-01-01 20:52:10 Trip High 1st Stage Vibration VT-192 2.0
007 06-18-01 09:25:40 Alarm High 1 Stage Vibration
st VT-192 1.55
008 05-30-01 17:37:50 Trip High E-Stop
009 05-03-01 00:21:10 Alarm High 3rd Stage Inlet Temp TE-136 137
010 03-29-01 12:00:45 Alarm Low Water Flow
Protection History screen showing a low oil pressure alarm of 15.8 psig.
Trip Alarm Alarm Trip

Description Tag Low Low Data High High
1: System Air Pressure PT-100 70.0 98.2 110.0 110.0

2: 3rd Stage Discharge Pressure PT-106 101.1 130.0 135.0
3: Drive Motor Current IT-199 148 165 173
4: Oil Pressure PT-159 70.0 80.0 115 180 200
5: Oil Temperature TE-147 60.0 70.0 120 140 150
6: 1st Stage Vibration VT-192 0.23 1.50 2.00
7: 2nd Stage Vibration VT-194 0.14 1.50 2.00
8: 3rd Stage Vibration VT-196 0.17 1.50 2.00
9: Inlet Air Filter DPT-107 4.2 8.0
10: Motor Power JT-199 1014
Protection Running screen showing current data with alarm and trip set points.
4. Analyze the information and take appropriate action(s) to correct the cause of the malfunction.
(It may be necessary to consult the Troubleshooting guidelines, which follow.)
6—7
Drive Train Troubleshooting

Condition: Possible Causes:
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
Motor Overheating
Ambient temperature too high

Ventilation inadequate
Voltage low, high, or unbalanced
Motor Overload
Control settings improper
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
6—8
Troubleshooting
Drive Train Troubleshooting...continued

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—9
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
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.
6—10
Troubleshooting
Control System Troubleshooting...continued

Motor Overload
Maximum amp 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).
Compressor Control Performance Abnormal
Set points incorrect.
Sensor reading faulty.
Control valve(s) faulty.
Control system tuning faulty.
6—11
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
Water flow to cooler(s) insufficient

Coolant temperature too high
Intercooler(s)/aftercooler fouled
Hot air bypassing intercoolers/aftercooler
Coolant bypassing intercoolers/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
Check Valve Malfunction
Valve oversized
Seat or disc worn or dirty
Disc movement impaired
6—12
Troubleshooting
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
Water flow to cooler insufficient

Coolant temperature too high
Oil cooler fouled
Thermal mixing valve faulty
Oil heater thermostat faulty
Low Oil Temperature
Water flow through coolers excessive

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—13
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—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 Parts
¨ Lubrication System Parts
¨ Main Drive Coupling Parts
¨ Heat Exchanger 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, Cooper Turbocompressor offers
full aftermarket support. The array of aftermarket services includes inspection and repair, availability of
genuine JOY® and Cooper Turbocompressor 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 3000 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 Cooper Turbocompressor trained and authorized service
representative.
For parts and/or service, always contact an authorized Cooper Turbocompressor sales and service
representative or else contact the factory directly.
Parts Coordinator
or
Field Service Department
Cooper Turbocompressor
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 3000

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. In addition, in certain instances Cooper
Turbocompressor may change the part number and/or may substitute a part of equal or greater reliabil-
ity without notice.
The Returned Goods Policy

It is necessary to contact Cooper Turbocompressor 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

Cooper Turbocompressor recommends keeping a basic inventory of replacement and spare parts and stock-
ing 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 Cooper
Turbocompressor replacement parts and Cooper Turbocompressor approved supplies.
Cooper Turbocompressor will accept no liability for damages caused by use of non-
authorized parts, supplies, or service.
7—5
Recommended Periodic Maintenance Parts & SuppliesDescription

QtyTurbocompressor
Description Qty Cooper Turbocompressor
Part Number
Filters:
· Inlet Air Filter, Primary and Secondary Elements [A] [A]
· Bypass Valve Air Line Filter Element [B] P0540016-00074
· Oil Reservoir Vent Filter Element 1 P1404987-00014
· Oil System Filter Element (Single Filter Type) 1 P1404040-00207
· Oil System Filter Element (Dual Filter Type) 2 P1401435-01233
Lubricants:
· TurboBlendTM Lubricating Oil (5-gallon / 20-liter pail) [C] P1405340-00294
· TurboBlendTM Lubricating Oil (55-gallon / 210-liter drum) [C] P1405340-00295
· Oil Sample Kit 1 P1797385-00000
· Oil Pump Motor & Main Drive Motor Ball Bearing Grease 1 P1405340-00289
· Main Drive Coupling Grease 1 P1405340-00264
· Inlet Guide Vane Drive Screw Grease 1 P1405340-00288
· Bypass Valve Lubricant [D] 1 P1405340-00270
Parts:
Heat Exchangers (Figures 7—9 & 7—10)
· K-Seal 3 P1408800-04941
· Y-Gasket 6 P1408800-04926
· Header Gasket 3 P1793932-02100
· Front Tubesheet Gasket 3 P1793931-02100
· Rear Header Gasket (S-Tube Type Only) 3 P1793932-02101
· Oil Cooler Gasket Kit 1 P1405680-00002
Bypass Valve (Figure 7—15)
· Rebuild Kit [E] 1 MB408539-00098
· Seal Kit [E] 1 MB408539-00202
Discharge Air Check Valve (Figure 7—18)
· Check Valve, 3” 1 P0540024-00118
· Check Valve, 3” 1 P0540024-00185
· Check Valve, 4” 1 P0540024-00072
· Check Valve, 4” 1 P0540024-00183
Main Drive Coupling (Figure 7—8)
· O-Ring 2 P1406064-20018
· Gasket 2 P1406064-04117
Condensate Drains (Figure 7—11)
· Solenoid Valve, 110/120-Volt 3 P1401581-01302
· Solenoid Valve, 220/240-Volt 3 P1401581-01341
· Check Valve 3 P1401581-01303
· Gate Valve 3 P1401581-00757
Instrumentation (Figure 7—1)
· Vibration Probe [F] P1407030-02002
· Vibration Probe Extension Cable [F] P3403893-00006
· RTD (Temperature Transducer) [F] P3403629-01585
· Pressure Transducer [F] P0540089-00182
· Drive Motor Current Transducer 1 Contract Specific
Notes: [A] Refer to Figure 7—14, Inlet Air Filter Assembly
[B] Refer to Figure 7—15, Bypass Valve Assemblies
[C] Refer to Section 2, Specifications, for reservoir capacity information.
[D] Only one specific bypass valve requires lubrication. Refer to Section 5, Maintenance.
[E] Only one kit is required depending which valve has been supplied.
[F] 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 Cooper Turbocompressor 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 Cooper
Turbocompressor replacement parts and Cooper Turbocompressor approved supplies.
Cooper Turbocompressor will accept no liability for damages caused by use of non-
authorized parts, supplies, or service.
7—7
Professional Service Inspection Parts & Supplies

Description Qty Cooper Turbocompressor
Part Number
Gearbox:
· O-Ring, First Stage Inlet 1 P1406702-00395
· O-Ring, Second Stage Inlet 1 P1406702-00386
· O-Ring, Third Stage Inlet 1 P1406702-00383
· Seal, First Stage Diffuser 1 P1794323-00005
· Seal, Second Stage Diffuser 1 P1794323-00002
· Seal, Third Stage Diffuser 1 P1794323-00002
· O-Ring Lubricant 1 R1409584-00000
· Gearbox Splitline Sealant 1 R1405571-00012
Heat Exchangers: (Figures 7—9 & 7—10)
· K-Seal 3 P1408800-04941
· Y-Gasket 6 P1408800-04926
· Head Gasket 3 P1793932-02100
· Front Tubesheet Gasket 3 P1793931-02100
· Rear Header Gasket (S-Tube Type Only) 3 P1793932-02101
Lubrication System:
· Oil Cooler Gasket Kit [A] 1 P1405680-00002
· Oil Reservoir Vent Filter Element 1 P1404987-00014
· Oil System Filter Element (Single Filter Type) 1 P1404040-00207
· Oil System Filter Element (Dual Filter Type) 2 P1401435-01233
Filters:
· Inlet Air Filter, Primary Element [B] [B]
· Inlet Air Filter, Secondary Element [B] [B]
Control Valves:
Inlet Guide Vane (Figure 7—13)
· Gasket, Inlet Guide Vane, 6” (150 mm) 1 P1409511-00000
· Gasket, Inlet Guide Vane, 8” (200 mm) 1 P1409511-00001
· Grease, Inlet Guide Vane Drive Screw 1 P1405340-00288
Bypass Valves (Figure 7—15)
· Seal Kit [D] 1 MB408539-00098
· Grease, Valve [C] 1 P1405340-00270
· Seal and Rebuild Kit [D] 1 MB408539-00202
· Bypass Valve Air Line Filter Element [E] 1 P0540018-00074
Drive Motor:
Main Drive Coupling (Figure 7—8)
· O-Ring 2 P1406064-20018
· Gasket 2 P1406064-04117
· Grease, Coupling 1 P1405340-00264
Main Drive Motor
· Grease, Ball Bearing 1 P1405340-00289
Notes: [A] For standard size cooler. Refer to Tables 7—6 and 7—7 for verification of oil cooler sizing and/or part number.
[B] Refer to Figure 7—14, Inlet Air Filter Assembly
[C] Only one specific bypass valve requires lubrication.
Refer to Section 5, Maintenance.
[D] Refer to Figure 7—15, Bypass Valve Assemblies
[E] Both bypass valves require this same filter element.
Table 7—2 Professional Service Inspection Parts and Supplies
7—8
Parts and Service
07
Control System Parts
02/12
01 11
05
04/06/14/15
03
17
13
Figure 7—1. Control System Sensors
Item Cooper Turbocompressor
No. Description Qty Part Number
Standard Instrumentation:
01 Vibration Probe, Stage 1 1 P1407030-02002
02 Vibration Probe Extension Cable (10 ft / 3 m) 1 P3403893-00006
03 RTD, Inlet Air Temperature, Stage 2 or 3 [A] 1 P3403629-01585
04 Transducer, System Gas Pressure 1 P0540089-00182
05 RTD, Oil Temperature 1 P3403629-01585
06 Transducer, Oil Pressure after the Filter 1 P0540089-00182
07 Tranducer, Drive Motor Current 1 Contract Specific
Optional Instrumentation:
11 Vibration Probe, Stages 2 and/or 3 1-2 P1407030-02002
12 Vibration Probe Extension Cable (10 ft / 3 m) 1-2 P3403893-00006
13 RTD, Inlet Air Temperature, Stage 2 [A] 1 P3403629-01585
14 Transducer, Compressor Discharge Pressure [B] 2 P0540089-00182
15 Transducer, Oil Pressure before the Filter [C] 1 P0540089-00182
16 RTD, Miscellaneous Temperatures (Not Shown) [D] 1-5 P3403629-01585
17 Switch, Oil Reservoir Level 1 P0540061-00199
18 Transducer, Air Filter Differential Pressure [D] 1 P0540089-00059
Notes: [A] Air temperature into the last stage of compression is standard. Alternate
locations are supplied as options.
[B] Required for all control methods.
[C] Reguired for filter differential pressure measurement.
[D] Shipped loose for field installation.
Table 7—3. Control System Sensors
7—9
01
03
02 04
(GEARBOX COVER)
(OIL/AIR SEAL)
(PINION)
Figure 7—2. Vibration Probe Installation

01 Vibration Probe 1 P1407030-02002
02 Retaining Plate 1 P1407301-00003
03 Capscrew 1 P0902224-00412
04 Tube Fitting 1 P1791399-03539
05 Silicone Adhesive [A] 1 R1405571-00005
Notes: [A] Apply adhesive to threads of capscrew and tube fitting.
Table 7—4. Vibration Probe Installation
7—10
Parts and Service
01 02 03
04
08 07 06 05
Figure 7—3. Low-Voltage Compartment/Vantage Control Components

No. Description Part Number Qty
01 User Interface Module (UIM) P3798102-00010 1
02 Main Logic Module (MLM) P3798102-00000 1
03 Actuator Motor Capacitor* 110 VAC P0540107-00012 1
220 VAC P0540107-00019
04 Control Relays (optional) Contact factory 1-4
05 Vibration Transmitters P3403893-00416 3
06 Pressure Transmitters P0540089-00140 2
07 Display Cable P3798102-00020 1
08 Emergency Stop Button P0540056-00221 1
* If Required
Table 7—5. Vantage Control Panel Components
7—11
Lubrication System Parts

09
12
11
10
Nut
Filter Housing
12
Nut
Figure 7—4. Reservoir Vent Filter Assembly

01 Main (shaft-driven) Oil Pump 1 P1401428-00614
02 Drive Coupling, Main Oil Pump 1 P1402070-00254
03 Auxiliary (motor-driven) Oil Pump 1 P1401428-00604
04 Motor, Auxiliary Oil Pump
- 230-460 Volt / 60 Hz 1 P1402068-00728
- 220-380 Volt / 50 Hz 1 P1402068-00728
- 380 Volt / 60 Hz 1 P1402068-00732
- 400, 415 & 440 Volt / 50 Hz 1 P1402068-00728
- 400 Volt / 50 Hz (CE Mark) 1 P1402068-00734
- 440 Volt / 60 Hz 1 P1402068-00735
05 Drive Coupling, Auxiliary Oil Pump 1 P1402070-00249
06 Pressure Regulator (Relief Valve) 1 P1401581-01707
07 Cooler, Oil-to-Water (Heat Exchanger):
- Complete Unit with 0.375” (10 mm) dia. copper tubes 1 P1401429-00981
- Maintenance Gasket Kit 1 P1405680-00001
08 Filter:
- Complete Assembly 1 P1401435-00289
- Replacement Element 1 P1404040-00207
Reservoir Vent Assembly (Figure 7—4):
09 - Ejector 1 P1403262-00107
10 - Filter (complete assembly) 1 P1401435-00228
11 - Replacement Filter Element 1 P1404987-00014
12 - Filter Seal Kit 1 P1401435-00229
13 Level Gauge 1 P1401582-00014
Table 7—6. Standard Lubrication System Components
7—12
Parts and Service
Lubrication System Parts
Figure 7—6. Reservoir Level Switch Option
Figure 7—5. Duplex Oil Filter Option
Figure 7—7. Reservoir Heater Option

14 Cooler, Oil-to-Water (Heat Exchanger): [A]
- Complete with 0.375 (10mm) dia. 90/10 alloy tubes [B] 1 P1401429-01002
- Maintenance Gasket Kit 1 P1405680-00001
15 Duplex Filter (Figure 7—5): [A]
- Complete Assembly 1 A3401435-00232
- Replacement Element 2 P1401435-01233
16 Level Switch (Figure 7—6) [A] 1 P0540061-00199
17 Temperature Regulator [A] 1 P1401581-01347
18 Oil Heater (Figure 7—7): [A]
- 230 Volt 1 P0540063-00157
- 380 Volt 1 P0540063-00176
- 400 Volt 1 P0540063-00320
- 415 Volt 1 P0540063-00190
- 440 Volt 1 P0540063-00332
- 480 Volt 1 P0540063-00155
- 575 Volt 1 P0540063-00156
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.
[B] Direct replacement for P1401429-00981.
Table 7—7. Optional Lubrication System Components
7—13
Main Drive Coupling Parts
01 KEY
O-RING
BOLT SLEEVE
GASKET HUB
NUT 02 SPACER
BULLGEAR
KEY SHAFT
LUBE PLUG
BAFFLE (2 PER SLEEVE)
PLATE GASKET
BAFFLE 02 NUT
PLATE
DRIVER HUB
SHAFT SLEEVE BOLT
O-RING
01
Figure 7—8. Main Drive Coupling Assem-

bly

01 O-Ring 2 P1406064-20018
02 Gasket 2 P1406064-04117
03 Grease 1 P1405340-00264
Table 7—8. Main Drive Coupling Maintenance Parts
7—14
Parts and Service
Heat Exchanger Parts

04
Y-Gasket
02
01
K-Seal
Upper Baffle Plate
Intercooler Bundle
Header Gasket
03
Water Header
Figure 7—9. Intercooler/Aftercooler Bundle Assembly
Standard U-Tube Model

01 K-Seal 3 P1408800-04941
02 Y-Gasket 6 P1408800-04926
03 Header Gasket 3 P1793932-02100
04 Front Tubesheet Gasket 3 P1793931-02100
Table 7—9. Intercooler/Aftercooler Maintenance Parts

Standard U-Tube Model
7—15
Rear Water
Header
Gasket
05
K-Seal Y-Gasket
01 02
04
Upper Baffle Plate
Intercooler Bundle
Header Gasket
03
Water Header
Figure 7—10. Intercooler/Aftercooler Bundle Assembly

Optional S-Tube Model

01 K-Seal 3 P1408800-04941
02 Y-Gasket 6 P1408800-04926
03 Header Gasket 3 P1793932-02100
04 Front Tubesheet Gasket 3 P1793931-02100
05 Rear Header Gasket 3 P1793932-02101
Table 7—10. Intercooler/Aftercooler Maintenance Parts
Standard S-Tube Model
7—16
Parts and Service
03
03
01
02
Figure 7—11. Solenoid-Operated Condensate Draining System

(One set required for each heat exchanger)

01 Solenoid Valve, 1/2” NPT, 110/120-Volt 1 P1401581-01302
01 Solenoid Valve, 1/2” NPT, 220/240-Volt 1 P1401581-01341
02 Check Valve, 1/2” NPT 1 P1401581-01303
03 Gate Valve, 1/2” NPT 2 P1401581-00757
Table 7—11. Solenoid-Operated Condensate Draining System
04
Vent Air
Discharge Line
01 01
03
T Drain Line
Heat Exchanger
02
Figure 7—12. LiquidatorTM Pneumatic

Condensate Drain System
Figure 7—13. LiquidatorTM Pneumatic
Condensate Drain Trap

01 Liquidator Drain Trap 1 P1797145-00000
02 Gate Valve, 1/2” NPT 2 P1796081-00007
03 Check Valve, 1/2” NPT 1 P1401581-01303
04 Ball Valve, 1/4”-NPTF 1 P1401581-01450
05 Tube Fitting, 1/4”-TUBE / 1/4”-NPTM 3 P0902962-00044
-- Condensate Kit (containing all the above parts) 1 MB408187-00100
Table 7—12. LiquidatorTM Pneumatic Condensate Draining System Components
7—17
Air Piping Parts
Inlet Guide Vane Assembly

01
01
02
Figure 7—14. Inlet Air Piping Components

01 Startup Screen (for 8” pipe) 1 P1405344-00016
02 Expansion Joint (for 8.625” O.D. pipe) 1 A3404999-00000
Table 7—13. Inlet Air Piping Components
7—18
Parts and Service
Air Piping Parts
05
04
02, 03
01
06
07
Figure 7—15. Inlet Guide Vane and Actuator Assembly

6” (150mm) 8” (200mm)
01 Inlet Pipe Reducer 1 P1409508-00000 P1409508-03000
02 Pipe Couping 1 P1404961-00200 P1404961-00209
03 Gasket, Pipe Coupling 1 P1404961-00602 P1404961-00607
04 Inlet Guide Vane Assembly 1 A3409140-00200 A3409140-00100
05 Gasket, Inlet Guide Vane 1 P1409511-00001 P1409511-00001
06 Actuator Assembly, 110/120-Volt 1 A3408596-03000 A3408596-03000
Actuator Assembly, 220/240-Volt 1 A3408596-03050 A3408596-03050
07 Actuator Motor, 110/120-Volt [A] 1[A] P1408596-00100 P1408596-00100
Actuator Motor, 220/240-Volt [A] 1[A] P1408596-00500 P1408596-00500
Notes: [A] The actuator motor is included in the actuator assembly.
Table 7—14 Inlet Guide Vane and Actuator Components
7—19
Air Piping Parts
02
01
Figure 7—16. Inlet Air Filter Assembly

AI-128-V Type [A]
01 Primary Filter Element [C] P1400009-00770
02 Secondary Filter Element [C] P1400009-00771
AI-128 Type [B]
03 Primary Filter Element [C] P0540009-00089
04 Secondary Filter Element [C] P0540009-00090
Notes: [A] Characterized by 18” x 18” (450 mm x 450 mm) elements
[B] Characterized by 24” x 24” (835 mm x 835 mm) elements
[C] Quantity could be 2, 3 or 4, dependent upon the number of inlet ports on the filter housing.
Table 7—15. Inlet Air Filter Replacement Elements
7—20
Parts and Service
Air Piping Parts

Figure 7—17 Bypass Valve Assemblies and Packaging Options
01, 02
04
01, 02 04
03
03 05, 06
05, 06
09 07, 08
01, 08
01
01

<600 Hp [A] >700 Hp [A]

01 Bypass Valve:
- 120 V / 60 Hz 1 P1401581-01256 P1401581-01501
- 220 V / 50-60 Hz 1 P1401581-01259 P1401581-01501
02 Kit, Seal or Rebuild 1 MB408539-00098 MB408539-00202
03 Solenoid Valve:
- 60 Hz 1 [B] P1401581-01166
- 50 Hz 1 [B] P1401581-01233
04 Metering Valve 1 P1409585-00000 P1409585-00000
05 Air Line Filter 1 P0540016-00091 P0540016-00073
06 Air Line Filter Element 1 P0540016-00074 P0540016-00074
07 Pipe Coupling Housing [C] 2 P1404961-00628 P1404961-00603
08 Pipe Coupling Gasket [C] 2 P1404961-00259 P1404961-00604
09 Flange Gasket [C] 1 (Not Required) P0907411-00008
Notes: [A] Compressor Power Rating.
[B] Included with Item #01.
[C] Parts for the packaging option. See figures above.
Table 7—16 Bypass Valve Assemblies and Packaging Options Components
7—21
Air Piping Parts
Volume Booster
Diaphagm
Actuator
Filter Regulator Transducer
Figure 7—18. Modulating Blow-Off Valve (MBOV) Assembly
Control Valve

01 Modulating Blow-Off Valve Assembly [A]
- 1.5” (40 mm) 1 P0540008-00780
- 2.0” (50 mm) 1 P0540008-00781
- 2.5” (65 mm) 1 P0540008-00782
- 3.0” (75 mm) 1 P0540008-00783
Notes: [A] Valve assemblies are complete with these components mounted and integrally piped:
diaphragm actuator, filter regulator, volume booster, and I/P transducer.
Table 7—17. Modulating Blow-Off Valve Assemblies
7—22
Parts and Service
Air Piping Parts

Actuator
Figure 7—19. Blow-Off
Silencer
Solenoid
Filter Regulator
Lock-Out
Valve
Valve
Body
Figure 7—21. Automatic Block Valve
Figure 7—20. Discharge Air
Assembly
Check Valve
Connections
Model Overall Cooper Turbocompressor
Inlet [A] Discharge [A] Length Part Number
BMSV-8 2” (NPT)[B] 8” (Flanged) 78” (2000 mm) P0540010-07091
BMSV-6 1 1/2” (Flanged) 6” (Flanged) 65” (1650 mm) P0540010-00104
BMSV-8 2” (Flanged) 8” (Flanged) 78” (2000 mm) P0540010-02082
LCV-10 3” (Flanged) 10” (Flanged) 71” (1800 mm) P0540010-07092
Notes: [A] Expressed per ANSI (USA) Standards for piping (in inches).
[B] Taper-Threaded. National (USA) Pipe Thread (in inches).
Table 7-18. Blow-Off Silencers
Description Part Number
3” Valve P0540024-00118
3” Valve P0540024-00185
4” Valve P0540024-00072
4” Valve P0540024-00183
Table 7-19. Discharge Air Check Valves
Description Part Number
3” Valve, 110/120-Volt P0540008-00809
3” Valve, 220/240-Volt P0540008-00822
4” Valve, 110/120-Volt P0540008-00800
4” Valve, 220/240-Volt P0540008-00823
Table 7—20. Automatic Block Valve Assemblies
7—23
7—24
Installation
Appendix A
Installation
In this appendix, the reader will learn about:
¨ The Installation Work Schedule
¨ Labor, Supplies, Equipment ….
¨ Site Considerations
¨ Process Air Piping
¨ Utility Piping
¨ Electrical Interface
¨ Receiving, Lifting, Moving ….
¨ Preparing for Startup
¨ Preventing Startup Problems
¨ The Inspection Prior to Initial

Startup Schedule
¨ The Initial Startup Procedure
¨ Service Assistance
A—1
A—2
Installation
Advance planning and preparation will help to simplify and expedite the compressor installation
process. This Installation Appendix gives an overview of the entire process, from preliminary site prepa-
ration 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 Cooper Turbocompressor trained and authorized service representative
will thoroughly inspect the installation work completed including all peripheral piping and electrical
work. He will check the lubrication system, adjust the control system (if necessary), verify motor align-
ment, start the compressor and instruct operating personnel.
For more information about specific procedures and/or illustrations of particular arrangements, refer to
the appropriate subsection in this appendix or other relevant appendices.
A—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 com-
pressor until the time of installation.
4. At least two weeks before the projected initial startup date, contact a Cooper Turbocompressor
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. *
9. Fabricate a manifold to connect the intercoolers and the oil cooler. *
10. Install all piping between the compressor and the main coolant lines.
11. Fabricate the condensate drain pipes and control devices. *
12. Connect the instrument air line to the reservoir vent ejector system.
13. Make all electrical connections.
14. 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 Cooper
Turbocompressor. When included from the factory, considerable savings can be realized at
installation. Details of these options are included later in this manual.
A—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 3000 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
Turbine oil (See Specifications)
Coupling grease (See Specifications)
Motor bearing grease (See Specifications)
Equipment *
Main drive motor controller (starter)
Oil pump motor starter and Oil heater contactor (if necessary)
Inlet air filter
Inlet startup screen
Expansion joints (for inlet and discharge piping)
Vent silencer
Condensate traps, or valves
Air system block valve
Cooling water control valves
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
Drill motor
31/64”, “S”, or 12.30 mm drills (for doweling of motor)
0.499”, or 12.67 mm reamer (for doweling of motor)
*Some equipment may have been purchased with the compressor. Check engineering documents provided
separately for definition of Cooper Turbocompressor’s scope-of-supply.
**All fasteners are in U.S.A. units (inches).
Table A—1. Materials Required for Compressor Installation
A—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 instal-
lation 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 3000 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
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. In particular, be sure to locate the air filter at least 10 ft. (3.3 m) above ground
level and 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 A—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. In the front, allow at least 6 ft. (2 m) for intercooler and
aftercooler bundle removal.
Ventilation
If installing the unit in a confined area, be certain to provide adequate ventilation to dissipate heat
generated by the package. The temperature immediately surrounding the compressor package
should not exceed 100°F (40° C).
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.
A—6
Installation
Water Supply and Drains

If water is to be used as the coolant, whenever possible provide clean cooling water with low mineral
content. This will optimize cooler performance and significantly reduce the possibility of cooler fouling
during operation.
Also, be sure to provide adequate open drains to carry away condensate from the intercoolers and
aftercooler. Condensate from the Turbo Air 3000 Compressor is completely oil-free and environ-
mentally safe.
(Refer to the Utility Piping subsection for additional information and requirements for water supply
and condensate drain piping.)
Foundation
The Turbo Air 3000 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).
· It must be isolated from vibrations from surrounding equipment.
· Flatness must be 0.010 in. per foot (1 mm per meter).
78 inches
(2000mm)
134 inches
(3400mm) 72 inches
(1800mm)
Figure A—1. Compressor Envelope
A—7
Process Air Piping

The process air system includes three subsystems: the inlet air piping, the discharge air piping, and the
bypass piping arrangements. The Process and Instrumentation Diagram provided separately illustrates
only the various compressor system components supplied by Cooper Turbocompressor. The user must
provide all external process air piping and supports as well as the piping design itself.
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 transmitted 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.
A—8
Installation
E G
F
D
1/2” Instrument Line C
A. Inlet Filter
B. Inlet Screen
C. Expansion Joint
C
B D. Check Valve
E. Block Valve
F. Blowoff Valve
G. Silencer
Figure A—2. Typical Process Air Piping
A—9
Inlet Air Piping

Figure A— 4 shows a typical inlet air piping arrangement in detail, including various standard and
optional components.
A. Inlet Filter Silencer

B. Pipe Reducer
C. Inlet Startup Screen
A D. Inlet Expansion Joint
E. Inlet Guide Vane (IGV)
F. IGV Motor
F
12” Recommended Pipe Size
C D STG. 1
E
B B
Figure A—4. Inlet Air Piping
When designing and installing the inlet air piping, it is important to carefully consider the following
information and recommendations.
Connection
The inlet air connection to the Turbo Air 3000 Compressor is a cast iron reducer, the outside of which
matches standard steel pipe. (American National Standards Institute: ANSI B36.10). This inlet reducer
may be removed and machined to accept a number of different style couplings, thus allowing the
installer to select among several options when making the inlet air pipe attachment to the compressor.
Figure A—5 shows a detail of the inlet air piping arrangement. (The Inlet Air Startup Screen and Inlet
Expansion Joint options are also included in this arrangement. Refer to relevant headings for more
information about these components.)
Do not make the final inlet air pipe connections to the compressor. The Cooper Turbocompressor
representative must inspect the piping for cleanliness during the startup service call before the final
connection is made.
A—10
Installation
Inlet Guide Assembly
Inlet Startup Screen
Inlet Expansion Joint
Figure A—5. Detail of Inlet Air Connection with Options
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 com-
pressor 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.
Fabrication
Use 8” or larger (or comparable size) pipe to connect the inlet air filter to the compressor. Do not use
pipe smaller than 8” (or comparable size), since the smaller size will cause reduced inlet air pressures
and impaired compressor performance.
Provide a straight run of approximately four pipe diameters before the inlet guide vanes (IGV’s) to
minimize flow distortion. Also, avoid using many elbows and sharp bends in the compressor inlet
piping.
A—11
Inlet Expansion Joint

Cooper Turbocompressor recommends the use of the Inlet Expansion Joint option (which consists of a
rubber sleeve with stainless steel clamps) as a means of joining the inlet air pipe to the compressor.
(See Figure A—5.) When making this connection, do not use pipe smaller than the recommended pipe
size; larger pipe is in fact preferable, since the increased volume will reduce both noise and pressure
loss.
Inlet Air Startup Screen

The inlet piping must be designed to prevent any solids from entering the compressor inlet. When long
runs of inlet piping are required, or when visual/physical inspection of the finished piping is difficult,
the temporary conical Inlet Air Startup Screen option serves to filter substances from the intake air
supply before they can reach the compressor and damage internal components. In such instances, it is
important to locate the screen as close as possible to the compressor inlet. The Inlet Air Startup Screen
is shown in Figure A—6.
CAUTION:
Be certain to remove the Inlet Air Startup Screen after approximately 40-50 hours of
compressor operation. If it is not removed, the pressure loss across the screen can signifi-
cantly reduce overall compressor performance.
Outer Screen
(10 x 10 Mesh / .32 wire)
Inner Screen
(8 x 8 Mesh / .063 wire)
8” (200mm)
Material:
302 or 304
Stainless Steel
12” (300mm)
Figure A—6. Inlet Air Startup Screen
Inlet Filter/Silencer
The Inlet Filter/Silencer option will remove airborne particles that would otherwise erode aerodynamic
components, foul heat exchangers and tend to accumulate within the air flow passages. The silencer
feature of this component will reduce compressor noise that travels through the inlet air piping. The
inlet filter/silencer is a permanently installed component.
A—12
Installation
Discharge Air Piping

The discharge air piping system is shown schematically in Figure A—7. It consists of the piping and
other accessories required for a specific installation, including a receiver, a block valve, a check valve,
and expansion joints.
A. Aftercooler 1. From last stage of compression.

B. Flexible Pipe Coupling 2. To compressed air system.
C. Victaulic Flange (option) 3. To bypass valve for venting.
D. Check Valve 4. To control panel - system pressure.
E. Block Valve 5. To control panel - compressor discharge pressure
A
5
Recommended
Pipe Size
C
1 B
4” 4”
2
D E
Figure A—7. Typical Discharge Air Piping Arrangement
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 machined to accept a Victaulic pipe coupling. When attach-
ing the discharge pipe, refer to the contract-specific Installation Arrangement Drawings supplied
separately for specific size information.
Cooper Turbocompressor offers the following coupling options:
· Straight Coupling
· Reducing Coupling
· Vic-Flange Adapter
A—13
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. Cooper Turbocompressor 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.
Cooper Turbocompressor recommends that all pressure-holding pipe be in accordance with the stan-
dards 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. When fabricating the dis-
charge piping system, do not exceed specified pipe volumes (0.1% of design flow in cubic feet
per minute) between the compressor discharge flange, the blow-off valve, and the discharge
check valve. (Additional information about blow-off valve and check valve installation is included later
in this appendix.)
WARNING:
Do not exceed the 400 lb. (1700 Nm) Maximum Allowable Force or the Maximum Allow-
able moment of 600 lbs. (800 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.
With all control methods, it is necessary to keep the pipe volume between the compressor discharge
connection, the discharge check valve, and the blow-off or bypass valve minimal. For proper operation
of the discharge check valve, 18” (450mm) of straight piping should precede and follow the valve.
A—14
Installation
CAUTION:
To assure proper compressor unloading, do not allow the pipe volume to exceed 0.1% of
the volume flow in cubic feet per minute (CFM). Excessive volumes may cause compressor
surging during unloading.
Discharge Expansion Joint

Cooper Turbocompressor 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.
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. (Refer to the Engineering drawings
supplied separately for the precise location of the discharge piping.)
Cooper Turbocompressor supplies a contoured, disc-type check valve that must be mounted properly so
as to pivot open and close. It is necessary to install this valve in a horizontal run of piping, with a
recommended minimum of four pipe diameters of straight pipe before and after the valve. In order to
hold the valve disc in a fully opened position, a flowing differential pressure of 0.5 psi (0.3kPa) is
required. If the valve is not correctly sized (particularly if it is oversized), the potential for shut-off
failure is increased. Before installing the check valve, refer to the Check Valve Installation drawing and
examine the valve itself for the top marking to determine the correct orientation.
WARNING:
Before operating the compressor, examine the top of the check valve to be sure that
the orientation of the valve is correct. Cooper Turbocompressor will not accept
responsibility for damage or personal injury incurred as a result of improper installation
of the check valve.
A—15
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 60-psig air supply for a three-stage compressor or a 30-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 Cooper Turbocompressor EDR-A-008,
Automatic Block Valve, for additional information on the Automatic Block Valve option.
Control Valve Piping

Depending on the control method being applied, the Turbo Air 3000 will either completely or partially
unload whenever the capacity of the compressor exceeds the compressed air system’s demand. Under
AUTO-OFFLINE control, the compressor is unloaded by completely bypassing the compressed air system
and venting discharge air back to the inlet of the compressor or out to atmosphere. In other cases, a
portion of the discharge air is partially vented or blown-off in order to maintain Constant Pressure or
constant mass flow into the compressed air system.
Bypass Valve
The AUTO-OFFLINE Control method utilizes a pop-action bypass valve (BPV). The BPV operates in either a
fully open or fully closed position. The compressor owner/installer is responsible for the proper installa-
tion of this control valve (which is shipped separately) unless the Mounted Bypass Valve option is
purchased. (Refer to the relevant heading for additional information about that option.)
Modulating Blow-Off Valve (MBOV)

All control methods may utilize a modulating blow-off valve (MBOV) which operates in any position
from fully closed to fully open. A pneumatic actuator, and I/P transducer, a volume booster and a filter
regulator all come mounted and integrally piped to the valve body as a complete assembly. The owner/
installer is responsible for the proper installation of the MBOV, which is shipped separately.
A—16
Installation
Valve Installation
In instances when the bypass valve or the modulating blow-off valve is installed by the owner/installer,
the installation must be in a branch of the discharge piping located upstream from the discharge check
valve. (Refer to the Flow Schematic supplied separately for a placement illustration.)
The recommended maximum length for this line (which is located between the main process pipeline
and the venting valve) is 10 ft. (3 m). The size of the bypass or blow-off valve piping should match the
size of the valve itself. Figure A—8 shows the correct installation of the control valve when it is owner
installed.
CAUTION:
In order to ensure proper compressor unloading and to prevent surging, be certain to keep
the pipe volume between the compressor connection and the blow-off or bypass valve
minimal. To determine the specific maximum volume, multiply the compressor design flow
(CFM) by .001.
A. Compressor Flange
1. To compressed air system
B. Check Valve
2. Control signal from control panel
C. Block Valve
2
D. Bypass or Modulating Blow-Off Valve
E. I/P Transducer
F. Filter Regulator IP FR G
G. Source of Instrument Air E F
Vent
D H
Recommended
Pipe Size
4” 3” 3”
1
A B
C
Figure A—8. Blow-Off Piping Detail
Mounted Bypass Valve Option

The Mounted Bypass Valve option is available with the AUTO-OFFLINE Control method only. In such
instances, the valve is installed between the compressor inlet and the discharge piping and is electrically
connected to the Vantage Control Panel.
Including this option with AUTO-OFFLINE applications eliminates the necessity for owner installation of
the control valve. When this option is factory installed, the bypass air is re-circulated to the compressor
inlet. This also eliminates the necessity for separate atmospheric vent piping as well as for the Vent
Silencer option described under Sound Suppression.
A—17
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 sup-
pression, 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 Cooper
Turbocompressor Engineering Data Release EDR-A-005, Insulation for Noise Control, available upon
request.
Vent Silencer
Since the high-pressure air expansion across the blow-off valve creates considerable noise, Cooper
Turbocompressor recommends using the Vent Silencer option to reduce noise produced during com-
pressor operation. (This option is not required in instances when the Mounted Bypass Valve option is
included in the package.)
For maximum effectiveness, this silencer must be properly installed directly on the blow-off valve or the
bypass valve. Any additional piping should be the same size as the silencer discharge flange, and may
be extended beyond the silencer. The exhaust piping from the silencer should be sized for a maximum
back pressure of 5 psig (.3 bar) on the silencer.
To increase the exit area, cut the pipe end at a sharp angle as shown in Figure A—9. Since airborne
noise is directional, aim the discharge in a non-critical direction. Do not direct the exhaust pipe onto a
hard surface which could cause resonance.
Cut at sharp angle to

increase exit area Discharge
Figure A—9. Angled Pipe End
A—18
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 cooling water (coolant) piping for the four water-cooler heat exchangers.
· 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, Vantage 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.
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.
Cooling Water (Coolant) Supply Piping

The typical Turbo Air 3000 Compressor package includes four water-cooled heat exchangers (two
intercoolers, an aftercooler, and an oil cooler). Figure A—10 illustrates the manifolding of these heat
exchangers to provide a single feed connection and single return connection for cooling water at the
compressor. Figure A—10 also shows the placement of a valve to throttle water flow to the oil cooler
to control oil temperature. (This throttle valve is required only when the Automatic Oil Temperature
Control option is not included at the time of order or has been retrofitted into the lubrication system.)
A—19
1-1/2” NPT
3/4” NPT
3” (76mm)
Recommended Pipe Size
Throttle Valve
Figure A—10. Typical Water Manifold
Figure A—11 illustrates a cooling water piping arrangement with typical feed and return piping, shut-
off valves, throttle valve, various gauges, and drain connections. Cooling water (coolant) requirements
are included in the Section 2, Specifications. The values given are representative of average usage.
Actual requirements may differ according to such variables as temperature, humidity, and the condition
of the heat exchangers. When the heat exchangers are regularly cleaned as described in Section 5,
Maintenance, significantly better performance will be possible.
The installer must consider the distance and routing of the water piping when determining the appro-
priate sizing for the piping. Cooper Turbocompressor also recommends installing, when necessary, a
pressure regulator to allow for pressure control of the water.
A—20
Installation
CAUTION:
When fabricating the coolant supply piping (Figure A—11), always install the throttle
valve on the discharge side of the manifold rather than the inlet side. This will ensure that
the coolers are always flooded and that no air locks will form to restrict flow.
After fabrication of the cooling water piping is complete and before the initial compressor startup,
install temporary filter screens in the supply lines just before entry to the heat exchangers. Flush the
pipes thoroughly, and when it is determined that the supply piping is completely free of any foreign
matter, remove the screens. Reconnect the compressor manifold, and verify that there are no external
leaks. To verify that there are no internal leaks, open the condensate drains of the intercoolers and
aftercooler.
C C
A. Temperature Gauge
B. Pressure Gauge
C. Shut-Off Valve
D. Throttle Valve
E. Drain Connection
3” Victaulic Connection D A
B A
E
B
Figure A—11. Typical Water Supply and Return Piping
A—21
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 condensate drains. Since the cooler cavities operate at different
pressures, manifolding will cause malfunctions due to excessive amounts of condensate
from higher pressure chambers being forced into lower pressure chambers and conse-
quently through the compressor.
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 Vantage Control System.
Three ½” NPT connections (one for each cooler cavity) are located at the front of the compressor. The
condensate piping and control devices attach to these connections. Figure A—12 illustrate a typical
condensate drain piping arrangement. It is also necessary to include a manual bypass valve and piping
with whichever type of drain control device is utilized. The isolation valves ahead of the control device
are optional.
It is also advisable to keep the condensate draining system open during shutdown to prevent conden-
sate accumulation in the compressor. This will also provide compressor protection in case of an inter-
cooler tube failure.
A. Hand Valve
B. Trap or Solenoid Valve
Figure A—12. Typical Condensate Removal Piping Arrangement
A—22
Installation
Optional Features
Cooper Turbocompressor offers an array of cooling water piping and condensate drain options that
may ease the installation of the compressor or enhance the overall operation of the compressor. Any
of these features may be easily retrofitted if not included at the time of the original machine order.
These are briefly described below.
Cooling Water (Coolant) Manifold Option

When this option is selected, the intercoolers, aftercooler, and oil cooler are manifolded to single inlet
and outlet connections. The Cooper Turbocompressor design is compact and precise and will reduce
installation time.
Figure A—13. Cooling Water Manifold Option
Automatic Cooling Water Shutoff Valves

This option includes a pair of solenoid operated valves to be installed at the inlet and outlet connection
points of the water manifold. These valves will be controlled by the Vantage Control System to shutoff
water flow to the four water-cooled heat exchangers whenever the compressor is not running. This
feature is intended to save cooling water and the operator’s time to perform a normal compressor
shutdown.
Automatic Coolant Water Flow Control Valves

This option includes a temperature sensor/controller installed in the air stream and a throttling valve
installed in the water stream; thus reducing water consumption during compressor unloaded opera-
tion.
A—23
Condensate Drain Piping Option

When this option is purchased at the time of order entry, a piping assembly including a solenoid-
operated drain valve and manually operated bypass gate valve is fabricated and attached to the drain
connection of the intercoolers and aftercoolers. The solenoid-operated drain valves are in turn wired to
the Vantage Control Panel. The Vantage Control System will open and close the drain valves at set
intervals to drain accumulated condensate from the heat exchanger chambers.
The Cooper Turbocompressor design is again compact and very effective. It will save installation cost
and efficiently allow condensate to drain from the cooler chambers without wasting compressed air.
WARNING:
Remember that the outlets of these three drain assemblies must not be manifolded to-
gether. They must individually discharge into an open drain or trough to prevent conden-
sate from higher-pressure chambers being forced back into lower pressure chambers. This
is the single most common error made at the time of compressor installation.
A. Solenoid Drain Valve

B. Check Valve
C. Manual Bypass Valve
D. Manual Block Valve
C
10 inches
(250 mm)
A
B
Figure A—14. Condensate Drain Piping Assembly Figure A—15. LiquidatorTM Pneumatic
Condensate Drain Trap
Pneumatic Condensate Drain Option

Figure A—15 illustrates an alternate to the solenoid-operated drain valve system. The LiquidatorTM
Pneumatic Condensate Draining System option is a demand-operated trap that automatically drains
condensate without any loss of compressed air. Significant energy savings could result when using this
system instead of other time-based draining systems. The Liquidator Draining System may be purchased
initially with the compressor or retrofitted later. Request additional information from an authorized
Cooper Turbocompressor representative. Engineering Data Release, EDR-D-005, explains this system and
provides complete installation, operation and maintenance information.
A—24
Installation
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 3000 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:
will 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. (Appendix B, The
Lubrication System, includes additional important information about the operation of the ejector/filter
system.)
Instrument Tubing
Figures A—2 and A—3 illustrate the external instrument tubing required to complete the compressor
installation. Pressure sensing points in the user’s discharge piping must be connected to pressure
transducers located on the compressor package. These pressure sensors are located in an enclosure
just underneath the Vantage Control Panel. Various applicable engineering drawings (supplied sepa-
rately) precisely locate the connection point(s) on the Turbo Air 3000 Compressor package, as well as,
schematically illustrate from where the tubing run(s) should originate.
The control method determines the number of instrument tubing runs that are required. 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.
A—25
Electrical Conduit
The typical Turbo Air 3000 Compressor installation will require that medium voltage, and possibly high
voltage, electrical power is delivered to complete the compressor installation. The standard package-
mounted components requiring electrical power are the main drive motor, the oil pump motor and the
Vantage Control Panel. Other optional equipment, such as the oil heater, will also require electrical
power. The National Electrical Code in the United States, as well as most other national codes, require
that the electrical wiring for this type industrial service must be encased in rigid conduit.
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.
A—26
Installation
Electrical Interface
The user is responsible for the proper electrical connection of several components at the site installa-
tion, including the Vantage Control Panel, the oil pump motor, the main drive motor, and the oil heater
option (if included). Refer to other technical data and/or engineering drawings supplied separately to
determine the correct power supply requirements.
WARNING:
Do not energize or start up the compressor until a Cooper Turbocompressor service repre-
sentative 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
Cooper Turbocompressor 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.
A—27
Main Drive Motor Controls

The major functions of a motor-control system are:
· Starting and stopping of the motor.
· Governing motor speed, torque, output (horsepower/kilowatts), and other characteristics.
· Protecting personnel and equipment.
When the main drive motor controller is purchased along with the compressor, Cooper
Turbocompressor specifies the proper hardware and design for easy compatibility with the compressor’s
Vantage Microprocessor Control System.
Cooper Turbocompressor Engineering Specification EDR-G-009, Requirements for Owner-Supplied

Motor Controls, completely details the minimum requirements for proper interface between the
compressor control system and the owner-supplied motor control equipment. However, because there
are different types of motor starting equipment and an even wider variety of optional features avail-
able, many factors have to be considered when making an appropriate choice.
There are two general categories of starters for single speed, squirrel cage induction motors, full
voltage starters and reduced voltage starters. When selecting the motor controls, consider the follow-
ing information about these two types.
Full Voltage Starters

These apply full-line voltage directly to the motor terminals and are available in many types, including
manual, magnetic, combination, and reversing. It is also possible to add several other functions to
improve protection or increase monitoring capability.
Reduced Voltage Starters

These systems, which limit the drive motor current inrush, work well when normal considerations for
use of reduced voltage starting are observed. Starting times for reduced voltage systems are generally
less than 30 seconds. However, with reduced voltage starters the compressor’s inlet guide vanes must
not be cycled open until the motor and compressor have reached full speed. (The Vantage Control
System has the capability to delay loading with a variable timer.)
Although two general types of reduced voltage starters are commonly used, stepped starters and solid
state starters, stepped starters have been shown to give more consistent and reliable performance. The
wide variety of solid state starting equipment, along with contributing effects of various options and/or
features, makes performance of solid state starters inconsistent and difficult to predict.
CAUTION:
It is advisable to use stepped starters for reduced voltage motor controls.
In certain applications, solid state starter performance may be unreliable or inconsistent.
Refer to Cooper Turbocompressor Engineering Specification EDR-G-008, Solid State Starter Specifica-
tions, for more information on minimal requirements for solid state starting equipment.
A—28
Installation
Oil Heater Option

The supply voltage determines the wiring method for the Oil Heater option. For typical wiring for
voltage applications of 480 VAC or less, refer to Figure A—19. With voltage applications greater than
480 and below 600 VAC, refer to Figure A—20 for a typical wiring diagram.
Three- L 3-1 L 3-1

Phase L 2-1 L 2-1
Power L 1-1 L 1-1
Heater Terminal Box (Front)

Heater Element Connections
CAUTION:
DO NOT CHANGE
JUMPER ARRANGEMENT
Thermostat
L 3-2 Three-Phase Power

L 2-2 From Three-Pole
L 1-2 Disconnect Switch
Figure A—19. Oil Heater Option Wiring (480 VAC or less)
Three- L 3-1 L 3-1

Phase L 2-1 L 2-1
Power L 1-1 L 1-1
Heater Terminal Box (Front)

Heater Element Connections
Thermostat
L 3-2 Three-Phase Power

L 2-2 From Three-Pole
L 1-2 Disconnect Switch
Figure A—20. Oil Heater Option Wiring (above 480 VAC and below 600 VAC)
Additional Wiring
Refer to contract-specific drawings to determine additional wiring requirements for other installation
options such as blow-off valves, water valves, transmitters, etc.
WARNING:
Remember that the control of hazardous energy sources is the responsibility of the com-
pressor installer and user, and that adherence to the guidelines above and any other
national or local codes is of critical importance. Failure to follow proper procedures may
result in equipment damage, and/or personal injury or death.
A—29
Receiving, Lifting, Moving, and Bolting

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 3000 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 contract-specific
engineering drawings supplied separately for as complete listing of equipment included in Cooper
Turbocompressor’s Scope-of-Supply.
Receiving
Cooper Turbocompressor personnel inspect each compressor thoroughly at the factory before ship-
ment. 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
The Turbo Air 3000 Compressor is a heavy and durable high technology product, but it can be dam-
aged as a result of improper treatment. It requires careful handling during all lifting and moving. The
unit includes clearly indicated lifting and moving points. Never use any other areas for lifting and
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.
The Turbo Air 3000 Compressor is designed to be moved with an overhead hoist and chain. Be sure that
both are properly rated for a maximum package weight of 18,500 lbs. (8400 kg), and be certain that
they are in good working order before attempting the move. Use the clearly designated lift points on
the compressor as shown in Figure A—21. (In some instances it may be necessary to use spreader bars
to clear certain main drive motors.)
WARNING:
Be certain to use properly rated equipment and lift the compressor only as shown at the
lift points indicated. Improper lifting may cause compressor damage and/or personal
injury.
A—30
Installation
Figure A—21. Compressor Lift Points
Moving
If an overhead hoist is not available, the compressor may be moved on rollers, dollies, or casters.
Alternatively, if a forklift is used to move the compressor, be certain to place the entire compressor on a
substantial pallet that supports the base between the liftpoints and lift only under the base between
the lift points indicated.
WARNING:
Before moving the compressor, verify that the moving device is the appropriate size and
sufficiently strong to bear the weight of the compressor. Improper moving may cause
compressor damage and/or personal injury.
Bolting
If the foundation has been properly prepared, the compressor may be put in place at this time. Cooper
Turbocompressor 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.
A—31
Preparing for Startup

Although each compressor undergoes rigorous and comprehensive testing before it leaves the manu-
facturing facility, after transit and installation it is necessary to test and recheck certain components on
site. Therefore, after all the preparations described previously are completed and 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 Cooper Turbocompressor
factory trained and authorized service representative should be present to inspect the site, supervise
the final installation steps, and assist with the startup procedure.
A Pre-Startup Inspection Checklist follows which arranges the tasks or responsibilities that the user or
installer should be able to complete prior to the arrival of the Cooper Turbocompressor startup repre-
sentative. Should any concerns or questions develop while executing this list, it should be brought to
the attention of the startup representative.
Additional tasks required, but not explained in earlier text include:

· Main drive motor rotation verification.
· Oil pump motor rotation verification.
· Lubrication system flush.
Instructions for each of these procedures are included after the Pre-Startup Inspection Checklist
(Table A—2).
WARNING:
Personnel safety and equipment protection must always be primary considerations during
compressor installation, startup, and operation. The high voltages associated with this
machinery, the shaft rotation speeds, and the highly pressurized process air produced by
the compressor are major safety hazards when proper safety precautions are not strictly
followed at all times.
The Prestart Inspection

Before performing the prestart inspection, review the Turbo Air 3000 Compressor installation instruc-
tions 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 Pre-Startup
Inspection Checklist in Table A—2.
A—32
Installation
Pre-Startup Inspection Checklist

Foundation Bolts
3 Properly tightened
Cooling Water (Coolant) Piping

3 Correctly routed and strain-free
3 Shut-off valves installed
3 Inlet and outlet correctly connected
3 Cleaned and flushed free of dirt and/or other foreign matter
Condensate Drain Piping

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

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

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

3 Correct pipe material and size
3 Properly supported, without excessive loads
3 Block valve installed
3 Check valve installed with recommended pipe volume
3 Bypass or Modulating Blow-Off Valve installed with recommended discharge pipe volume
3 Silencer installed (if required)
3 Clean and free of dirt and other foreign matter
Oil Reservoir Vent Ejector

3 Properly connected to a supply of clean, dry air
Table A—2 The Prestart Inspection Checklist
A—33
Pre-Startup Inspection Checklist continued…

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

3 Motor bearings properly lubricated
3 Motor rotation direction checked
3 Main drive coupling properly installed and lubricated
Lubrication System
3 Reservoir filled with correct type and quantity of oil
3 Reservoir vent filter trap filled with oil
3 Optional oil reservoir heater thermostat set to 100° F (40° C)
3 Pump motor bearings properly greased
3 Oil pump rotation checked
3 Pump operated for at least 2 hours to completely flush system
3 New oil filter element installed after system is flushed
3 No leaks detected when pump motor is operating
Control System
3 Air pressure transducers properly connected
3 Initialization checked
3 Setpoints checked
3 Inlet guide vane assembly operation checked
3 Bypass or Modulating Blow-off Valve operation checked
3 Current sensor checked
3 Probe gaps checked
Table A—2. The Prestart Inspection Checklist
A—34
Installation
Main Drive Motor Rotation Verification

Before coupling the compressor and main drive motor, it is necessary to verify that the phase sequence
wiring will provide the correct rotation direction.
To verify correct rotation, follow this sequence:
1. Verify that motor fastening bolts are properly torqued as listed in Section Two, Compressor Specifi-
cations.
2. Verify that the rating voltage and frequency shown on the motor nameplate match the power
supply.
3. Carefully follow all of the motor manufacturer’s instructions (provided under separate cover)
regarding preparation and installation.
4. “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.
5. If required, change the phase wiring to reverse the direction of rotation.
Oil Pump Motor Rotation Verification

This inspection is required to ensure that the oil pump will generate the required pressure during
startup and subsequent operation.
Confirm the correct rotation of the 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.
A—35
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 Cooper Turbocompressor 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 Cooper Turbocompressor service representative must observe this last inspection point and
(if required because of contamination) the changing of the oil filter element before the initial
compressor startup.
A—36
Installation
Preventing Startup Problems

It is the owner’s responsibility to plan for the inspection and initial startup service by the Cooper
Turbocompressor representative and to provide all tools, equipment, supplies, and labor required as
described earlier in this section. Contact the Cooper Turbocompressor service representative at least
two weeks before the required on-site date to arrange for startup service.
To ensure proper and safe compressor startup and operation, a Cooper Turbocompressor trained
and authorized service representative should be present to inspect the site and to assist in the
final installation steps and the initial startup procedure.
The list given in Table A—3 includes common problems and/or situations that may delay or unnecessar-
ily complicate the installation and initial start-up procedure. Avoid such situations, or correct them
before the Initial Startup Service Inspection. (Refer to the relevant heading in this Appendix for specific
information about each area.)
Potential Compressor Startup Problems

· Compressor damage during shipment.
· Compressor damage from improper lifting or from having been stepped on.
· Earth grounds not in place.
· Incorrect or incomplete electrical interface with motor controls.
· Incorrectly installed bypass or blow-off valve piping.
· Bypass valves not included on condensate drain piping.
· Condensate drain piping manifolded together.
· Reservoir vent ejector piping improperly installed.
· Excessive stresses on inlet, discharge, or water piping.
· 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.
· Contract-specific information (manuals and drawings) not available on site.
Table A—3 Potential Compressor Startup Problems
A—37
The Inspection Prior to Initial Startup Schedule

As part of the site evaluation, a factory trained and authorized Cooper Turbocompressor service
representative will verify that the compressor is ready to be put into full operation. The service repre-
sentative will 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. Inspect the compressor installation site, including other supporting air system equipment.
3. Verify that the discharge air piping complies with Cooper Turbocompressor design requirements as
stated in this manual as well as on the contract-specific drawings supplied separately. (This includes
checking the locations of control valves, the inclusion of a system block valve, compressor flange
load limits, etc.).
4. Verify that the inlet air piping complies with Cooper Turbocompressor design requirements as
stated in this manual and on contract-specific drawings supplied separately. (This includes checking
the location of the inlet air filter/silencer, the position of the inlet air startup screen, compressor
flange load limits, etc.)
5. Inspect the water and condensate drain piping for completeness.
6. Verify that all electrical connections have been made correctly.
7. Verify that the compressor oil reservoir is filled with TurboBlendTM Lubricating Oil.
8. Rotate the compressor bullgear and main drive motor shaft (while uncoupled) by hand to verify
that both rotate freely.
9. Check the rotation of the main drive and oil pump motors.
10. Make the final alignment of the motor shaft to the compressor shaft, doweling the motor in place
when complete.
11. Verify that the oil reservoir venting system is receiving the proper dry air supply.
12. Begin the lubrication system flush procedure.
13. Verify the temperature setting of the oil heater option (if included).
14. Make any necessary Vantage Control System adjustments to satisfy the user’s expected require-
ments.
15. Inspect the oil filter element and change it, if necessary.
16. Oversee the installation of the main drive coupling, the lubrication of the coupling, and installation
of the coupling guard.
17. Complete the Pre-Startup Inspection Checklist shown in Table A—2 with installation personnel
before the initial compressor startup procedure.
A—38
Installation
Initial Start-up Checklist

The instructions given here provide a sequence of steps to follow during initial compressor operation.
WARNING:
Do not attempt to start up the Turbo Air Centrifugal Compressor until after a CTC-
authorized service representative has fully inspected and approved the compressor
installation. Cooper Turbocompressor recommends that a trained and authorized service
representative perform the initial startup procedure.
Before Applying Power

Check the following before turning power on:
c Verify the manual block valve is closed.
c Check the location of the system pressure transducer.
c Check wiring for correctness, loose wires.
c Verify earth grounding.
c Check motor starter interface wiring from Vantage.
c Remove oil pump opto and motor circuit optos.
c Check Main motor and auxiliary oil pump overload settings.
c Check the supplied panel power.
Powered Pre-Start Checks

Apply power and perform the following checks before starting the compressor:
c Turn off access codes.
c Verify the configuration in the Vantage matches the configuration checked before
traveling to the job site and make any changes required.
c Check vibration probe gap.
c Verify the instrumentation (wiring & monitoring points).
c Verify valve operation.
c Verify the Vantage Maximum Motor Current setting equals the motor FLA.
c Turn-on oil reservoir vent ejector.
c Verify oil pump operation.
c Verify start-up status.
c Bump main motor verify rotation & re-couple.
c Turn on coolant.
A—39
Initial Start up Procedure

Start the compressor and:
1. Measure and record the acceleration time (___ seconds).
2. Unload the compressor.
3. Verify normal compressor operation while unloaded.
c Check inlet valve unloaded position.
c Check for oil and water leaks.
c Check and record operating levels.
c Check main motor for oil leaks and over heating.
4. Open inlet valve to maximum full-load amps.
5. Verify proper operation of the condensate removal system.
6. Tune Blow Off Discharge Pressure Loop.
7. Set BOV System Pressure loop tuning equal to BOV Discharge Pressure loop.
8. Tune Inlet Valve Maximum Load loop.
9. Set Inlet valve system pressure loop setting and Inlet minimum flow setting equal
to the Inlet valve maximum load loop setting above.
10. Tune inlet minimum flow control loop.
11. Setup the manual valve display.
12. Surge test the compressor.
c Surge point 1: Head__________, Power__________.
13. Setup Maintenance Performance control.
14. Setup Operator setpoints.
15. Unload compressor and open the block valve.
16. Place the compressor in Automatic and load.
17. Tune the Blow Off System Pressure loop.
18. Tune the Inlet System Pressure loop.
19. Place compressor in Automatic and observe proper control.
20. Shutdown compressor.
21. Correct the start sequence based on the actual acceleration time.
22. Reset the operation history.
23. Put in access codes.
A—40
Installation
Service Assistance
The Turbo Air 2000 Centrifugal Compressor is a high technology product. When problems develop
which are beyond the scope of operating personnel, request assistance from a Cooper
Turbocompressor trained and authorized service representative or the Cooper Turbocompressor Field
Service Department.
For any questions regarding installation, operation, or maintenance, or to schedule a service visit,
contact a trained and authorized Cooper Turbocompressor representative:
Authorized Cooper Turbocompressor Service
Name:
Address:
Phone:
or:
Field Service Department
3101 Broadway P.O. Box 209
Buffalo, NY 14425-0209 USA
Phone: (716) 896-6600
Fax: (716) 896-1233
A—41
A—42
Appendix B
¨ The Compressor Lubrication System
¨ Vantage Control of Compressor

Lubrication
¨ Operational Guidelines
¨ Gearbox and Reservoir Venting
¨ Optional Features
B—1
B—2
Unlike some other types of rotating equipment, high-speed, geared compressors cannot operate, even
for very brief periods, without adequate lubrication. The Turbo Air 3000 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, automatic temperature regulation,
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 2, Specifications, for information about
TurboBlendTM Lubricating Oil, and Section 7, Parts & Service, for replacement part numbering details.
B—3
The Compressor Lubrication System

Figure B—1 is a schematic illustration of the compressor lubrication system, indicating how the oil
circulates through the system and through standard compressor components. The following describes
the principles of normal operation.
Normal Operation
1. The main oil pump [B], mounted on the compressor gearbox and 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]. The throttle valve [E] in
the return water line regulates the flow of the cooling water through the oil cooler, thereby
keeping the temperature of the oil within the normal operating range.
3. The oil continues on to the oil filter [F] where impurities are removed.
Gearbox
G
Pinion Bearings [J] Manifold

H
Gear Spray Nozzles [K]
Bullgear Bearings [J]
Temperature
Regulator Sensor
L T
Pressure
Sensor
Bleed P
Valve
Lube Oil
Reservoir
A Check
Valve Main Oil Oil Filter
N Pump B F
Check
Auxiliary Valve
Oil Pump
M C
Water In
Water Out
E
Oil Cooler
D
Figure B—1 Compressor Lubrication System Schematic

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, where it passes around a baffle arrangement
that breaks down any foam before it is allowed to continue to recycle through the compressor
lubrication system.
6. The pressure regulator valve [L] maintains the correct operating pressure throughout the
lubrication cycle and returns any excess oil to the reservoir.

NOTE: The auxiliary pump does not run during normal operation. The main oil pump
provides full compressor oil flow and pressure requirements.
B—4
Vantage Control of Compressor Lubrication

Throughout the lubrication cycle, the Vantage control system continuously monitors the compressor
lubrication system to guarantee safe and efficient operation. The oil pressure sensor [P] and oil
temperature sensor [T], shown in Figure B—1, ensure that all critical mechanical components are
being properly lubricated and cooled by the oil.
These sensors allow the operator to see present lubrication system conditions on the Vantage display
panel. When operating conditions warrant, the control system will initiate either a compressor Alarm
condition or a compressor Trip condition (depending on the severity of the problem).
Full discussions of Alarm and Trip messages and compressor setpoints are included in Section Six,
Troubleshooting.
In addition to monitoring the operation of the lubrication system, the Vantage control system controls
the action of the auxiliary oil pump for the following two circumstances.
Startup Operation
1. Prior to the starting of the compressor, the motor driven auxiliary oil pump is energized. This
pump [M] draws oil from the reservoir and cycles it through the lubrication system and the
compressor gearbox. Check valve [N] prevents oil from being pumped back into the reservoir
through the main oil pump.
2. The oil flows through the lubrication system and compressor gearbox as described earlier.
3. The compressor may now be started following routine procedures.
4. After the compressor reaches full speed, additional oil pressure is present because both the shaft-
driven main oil pump and the auxiliary oil pump are feeding the system. The Vantage control
system shuts down the auxiliary pump if the oil pressure transducer [P] senses oil pressure greater
than the Lube Oil System High Pressure Set Point.
5. After the auxiliary oil pump shuts down, the lubrication system functions as described under
Normal Operation.
Shutdown Operation
1. Upon initiation of normal shutdown, the Vantage control system starts the auxiliary pump.
2. The auxiliary pump remains on for a set period to maintain lube oil pressure as the compressor
coasts to a full stop.
Emergency Operation
When a malfunction occurs during operation that results in a loss of oil pressure, the Vantage control
system operates the lubrication system in the following manner:
1. The oil pressure transducer [P] senses a pressure value below the Lube Oil System Low Pressure Set
Point. This causes the Vantage control system to activate an alarm condition that starts the
auxiliary pump.
B—5
2. The auxiliary pump, operating in tandem with the main oil pump, restores normal system oil
pressure and the compressor continues to operate.
3. A continued decrease in oil pressure initiates a trip condition and the Vantage control system shuts
down the main drive motor.
4. Similarly, if the oil temperature exceeds predetermined set points, the Vantage control system
activates an alarm condition or shuts down the compressor, depending on conditions.
Operational Guidelines
To obtain the best and safest operation of the Turbo Air Compressor, apply the following guidelines
and recommendations.
Oil Pump Operation

Cooper Turbocompressor recommends keeping the auxiliary oil pump in continuous operation (even
during 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.
B—6
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
The Turbo Air 3000 Compressor utilizes a simple venturi-type ejector/filter system to create a slight
vacuum inside the gearbox and oil reservoir. This vacuum 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 B—2.
WARNING:
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 B—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.
B—7
Optional Features
Although the following components are not required for safe operation of the Turbo Air 3000 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 Reser-
voir 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 B—3 shows the Oil
Heater option.
Figure B—3 The Oil Heater Option
Thermostatic Mixing Valve

With the standard package, oil temperature is maintained by regulating the flow of cooling water
through the oil cooler. This method, though effective, may require seasonal adjustments. Including the
Thermostatic Mixing Valve option will automatically control oil temperature by regulating the oil flow
around the oil cooler, thus keeping the temperature of the oil entering the compressor constant. The
Thermostatic Mixing Valve option is shown in Figure B—4.
From To
Oil Pump Oil Filter
Regulator
Water In
Water Out
Oil Cooler
Figure B—4 The Thermostatic Mixing Valve Option
B—8
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, Cooper
Turbocompressor offers the Duplex Oil Filter option. The duplex oil filter eliminates the necessity for
compressor shutdown during filter maintenance. (Refer to Section Five, Maintenance, for full instruc-
tions regarding this procedure.) The Duplex Oil Filter option is shown in Figure B—5.
Figure B—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
Vantage 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 B—6 shows the Oil Filter
Differential Pressure Monitoring option.
Oil from Cooler Oil to Gearbox
Oil Filter
Figure B—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 Vantage 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.
B—9
B—10
Vantage Control System Logic
Appendix C
¨ Compressor Control Methods
¨ AUTO-OFFLINE Control
¨ AUTO-STANDBY Control
¨ AUTO-UNLOAD Control
¨ Compressor Safety Mechanisms
C—1
C—2
This appendix provides detailed descriptions of each of the three compressor control methods. It
includes the theoretical basis, performance maps for each of the five control loops and their
associated setpoints for each operating method. This information is of a highly specialized nature and
not necessary required reading for all operating personnel. It is written only as a reference for skilled
technicians when it becomes necessary to fine-tune compressor controls or to troubleshoot various
operating conditions.
The reader should bear in mind that the information contained in this appendix covers various
optional features or options that may not be part of any specific compressor package or installation.
Before referring to this appendix, determine which specific optional features are included and which
operating method applies.
C—3
Control Methods
Vantage offers three distinct load control methods to provide flexibility in meeting widely varying
jobsite compressed air needs.
· Auto – Offline*
· Auto – Standby*
· Auto – Unload
Each Vantage control method uses all five valve control loops shown Table C—1. Detailed descriptions
of these methods appear latter in this Appendix.
*Note: Both the Auto-Offline and Auto-Standby mode require a modulating blow off
discharge valve.
Load Control Loops

The Vantage control system performs load control through five independent control loops. Each loop
modulates either the inlet valve or the discharge valve, also called the Modulating Blow Off Valve or
MBOV
Inlet Valve Control Discharge Valve Control

Control loop Setpoint Control loop Setpoint
Maximum Power Maximum Motor Load Blow-Off System System Pressure
Pressure Offset
System Pressure System Pressure Blow-Off Discharge Max. Discharge
Pressure Pressure
Minimum Flow Surge Control Offset
Table C—1 Vantage Control Loops and their Setpoints

A description of the setpoints follows.
C—4
Inlet Valve Control Setpoints

The Vantage control system modulates the compressor inlet valve in response to the control setpoints
associated with the three control loops described on the preceding page.
Each of the control loops constantly reviews the operational status of the compressor relative to its
setpoint. Vantage sends opening and closing signals to the inlet valve to maintain the desired system
pressure (System Pressure setpoint) and prevent the motor from overloading (Max Motor Load
setpoint), while protecting the compressor from surge (Surge Control Offset ).
All inlet valve moves are governed by user-set tuning parameters for each control loop. Control of the
inlet valve can be transferred among loops but the output of only one loop at a time can be in
control.
NOTE: The active control loop appears on the Performance Control tab of
the VIEW screen.
Maximum Motor Load Setpoint
Drive motor amperage is one indicator of the compressors’ output. Motor amps are directly
proportional to the position of the compressor inlet valve; as the inlet valve opens, the motor will
draw more amperage. However, the Maximum Motor Load setpoint establishes a limit on the opening
of the inlet valve to prevent running the motor in an overload condition. When displayed, this
setpoint value appears as a % of the motor’s nameplate full load amps (FLA).
System Pressure Setpoint
Within its motor amperage range, the inlet valve control loop will attempt to achieve the System
Pressure Setpoint. If this setpoint is exceeded, the inlet valve will be throttled accordingly. Under the
Performance Control tab, the System Pressure setpoint is identified as SP, where the actual system
pressure is shown as the process variable (PV).
Surge Control Offset
In the case of low plant demand, as the inlet valve closes, the flow through the compressor will
decrease and plant pressure levels will remain stable. However, if the flow drops too low the
compressor could surge. To prevent a ‘low-flow’ surge, Vantage maintains a minimum flow, using the
Surge Control Offset value as a setpoint. At all points along the Surge Control Offset line, Vantage
controls the actual system pressure to the System Pressure Offset setpoint.
When the system reaches this setpoint, control transfers to the compressor discharge valve control
loops.
NOTE: There is an ‘Output’ indication on the Vantage Performance Control screen that
shows the position of the inlet valve as a % of available flow.
In the case of an electrically actuated inlet valve, the Output indication will show the
direction of travel (+ for open; - for close) and how fast the inlet is opening or closing.
C—5
Discharge Valve Control Setpoints

This control mode functions exactly the same as Auto-Offline, up to the point where the check valve
closes. Then, instead of unloading, Auto–Standby opens the blow off valve further, to operate the
compressor at a discharge pressure (Standby Mode Offset) less than the System Pressure setpoint. This
method allows the unit to fully load much quicker, when the system pressure drops below the System
Pressure setpoint.
System Pressure Offset Setpoint
Under the inlet valve’s Minimum Flow control loop, Vantage allows the actual system pressure to
increase to the value of the System Pressure Offset setpoint.
A typical value for this setpoint is about 2 to 3 psi. above the System Pressure setpoint.
If this maximum system pressure is reached, Vantage will then modulate the compressor blow-off valve
(if it exists) to keep the plant’s pressure at the System Pressure Offset value.
The actual system pressure (displayed as PV under the Performance Control tab) is the same as in the
Inlet Valve Control section.
Note that the Vantage modulates the inlet valve to maintain system pressure, and it
modulates the blow off valve to maintain maximum system pressure.
Maximum Discharge Pressure Setpoint
Discharge pressure is the direct output pressure of the compressor, before the discharge check valve,
and air conditioning items (aftercoolers, dryers, etc). If the discharge pressure becomes too high, the
compressor will surge. Vantage uses the Maximum Discharge Pressure Setpoint to prevent surging. If
the Max Discharge Pressure setpoint is reached, that control loop will quickly modulate the blow off
valve to keep the discharge pressure under control.
The proper setting is for this setpoint is at a value above Max System Pressure, and below the
compressor’s high-pressure surge point.
Note: The position of the blow off valve can be seen on the Performance Control screen in the same
manner as that of the inlet valve.
C—6
Auto-Offline Control
With Auto-Offline Control, the inlet valve modulates to satisfy the System Pressure setpoint (within the
Maximum Motor Load setpoint limits). In cases of low demand, the control throttles back to the
Minimum Flow control line setpoint. The Minimum Flow control loop controls system pressure to the
System Pressure Offset setpoint and flow to the Surge Control Offset line. The compressor inlet valve
responds to the Surge Control line. If system pressure reaches its Offset value, Vantage modulates the
compressor’s discharge blow off valve. As the blow off valve reaches point of closing the discharge
check valve, Vantage unloads the compressor. When the system pressure drops below the System
Pressure setpoint, Vantage reloads the compressor through the inlet valve control loops.
Auto-Offline Control Setpoints

· Maximum Motor Load Setpoint: Prevents motor overload condition.
· System Pressure Setpoint: Establishes the initial pressure control point.
· Surge Control Offset Line: Prevents compressor surging at minimum flow conditions.
· System Pressure Offset: Sets an upper level for allowable system pressure.
· Maximum Discharge Pressure: Prevents compressor surging at over-pressure conditions.
Auto-Offline Control Steps (see Figure C— 1)

1. Compressor loads to achieve the System Pressure setpoint (position 1).
2. If demand is low, the inlet valve throttles to the Minimum Flow line (position 2).
3. The inlet Minimum Flow control loop operates the compressor along the Surge Control Offset line
(B), between position 2 and the System Pressure Offset setpoint (position 3).
4. At the System Pressure Offset setpoint (pos.3), control switches to the Blow Off System Pressure
control loop, which begins to modulate the compressor blow off valve.
5. If blow off increases to the point that the discharge check valve closes, Auto-Offline unloads the
compressor by first fully opening the blow off valve, and then closing the inlet (pos.4).
6. The compressor reloads when the system pressure drops below the System Pressure setpoint.
Figure C—1: Auto-Offline Control Operation

C—7
Auto-Offline Control
Inlet Valve Control

When the actual system pressure is lower than the System Pressure Setpoint, the Vantage controller
begins to load the compressor. During the initial load cycle, the inlet valve opens to a Minimum Flow
value when the compressor discharge valve begins closing.
During this initial load cycle, the Inlet Maximum Load control loop controls the inlet valve and quickly
loads the compressor within the Maximum Motor Load setpoint constraints.
Note: The proper Motor Load setting for 1.15 service factor motors is 112% of motor full
load amps (FLA).
As the system air pressure approaches the System Pressure setpoint, the Inlet System Pressure control
loop obtains control of the inlet valve (if the motor amps are below maximum).
In cases of low air demand, Inlet System Pressure control loop maintains the System Pressure setpoint
by reducing the compressor output through inlet valve throttling moves. This throttling continues
until the compressor reaches its minimum stable operating point, and the Inlet Minimum Flow control
loop resumes automatic control of the inlet valve.
In the Minimum Flow control loop, the inlet valve is controlled along the minimum flow Surge Control
Offset line, a user-set specific offset along the entire actual surge curve.
An important aspect of the Minimum Flow control loop, is that the actual system pressure is allowed
to increase above the System Pressure setpoint, to the System Pressure Offset setpoint. When the
measured pressure reaches the System Pressure Offset value, Auto-Offline then smoothly transfers
control to the compressor discharge valve control loops.
C—8
Discharge Valve Control Discussion

As explained, the Vantage discharge valve control loops do not come into play until system pressure is
allowed to increase to the System Pressure Offset setpoint. Until then the compressor discharge valve
remains fully closed.
Note: The System Pressure Offset setpoint for the blow-off control loop is displayed on
the right side the bar graph area of the Vantage Performance Control screen.
When system pressure rises above this offset value, the Auto-Offline control mode attempts to
modulate the compressor discharge valve under its Blow Off System Pressure control loop. If there is
no blow-off valve, the compressor unloads.
The blow off valve continues to open until the compressor’s discharge check valve closes. When the
check valve closes, Auto-Offline unloads the compressor by fully opening the blow off valve and closes
the inlet valve to its unloaded position.
The compressor continues to run unloaded until the actual system pressure drops to a level below the
System Pressure setpoint. Then it reload under inlet valve control, as before.
Vantage also has one more blow-off valve control loop to enhance control response time in certain
transitional periods.
The Blow Off Discharge Pressure control loop, and its corresponding Maximum Discharge Pressure
setpoint come into play under certain compressor operating conditions.
The Blow Off Discharge Pressure control loop provides a fast response when the discharge pressure
climb suddenly. This can occur because of a sticking check valve, closed block valve, or plugged dryer.
The proper setting of the Maximum Discharge Pressure setpoint is a value below the natural high-
pressure surge point of the compressor.
Although the Vantage control loops are tuned at Cooper Turbocompressor prior to shipment, it is
important to verify the tuning under the actual jobsite conditions.
Proper tuning is the key to quick and efficient interaction among the five control loops.
C—9
Auto-Standby Control
This control mode operates the same as Auto-Offline until the check valve closes. Then, instead of
unloading, Auto–Standby opens the blow off valve further to operate the compressor at a discharge
pressure (Standby Mode Offset) less than the System Pressure setpoint. This method allows the unit to
fully load more quickly when the system pressure drops below the System Pressure setpoint.
Auto-Standby Control Setpoints

· Maximum Motor Load Setpoint: Prevents motor overload condition.
· System Pressure Setpoint: Establishes the initial pressure control point.
· Surge Control Offset Line: Prevents compressor surging at minimum flow conditions.
· System Pressure Offset: Sets an upper level for allowable system pressure.
· Maximum Discharge Pressure: Prevents compressor surging at over-pressure conditions.
Auto-Standby Control Steps (see Figure C—2)

1. Compressor loads to achieve the System Pressure setpoint (position 1).
2. If demand is low, the inlet valve is throttled to the Minimum Flow line (position 2).
3. The inlet Minimum Flow control loop operates the compressor along the Min Flow control line
4. At the System Pressure Offset setpoint (pos.3), control switches to the Blow Off System
Pressure discharge control loop, which begins to modulate the compressor blow off valve.
5. If blow off increases to the point that the discharge check valve closes, Auto-Standby
continues to open the blow off valve until the compressor discharge pressure drops to the
Standby Mode Offset pressure , which must be below the System Pressure setpoint (pos.4).
6. The compressor reloads fully when the system pressure drops below the System Pressure
setpoint.
Figure C—2: Auto-Standby Control Operation

C—10
Auto-Standby Control
The Auto-Standby control method is for air systems that experience dramatic variations in demand yet
do not have a lot of receiver capacity. In these cases, an unloaded compressor may not be able to
respond fast enough to sudden increases in demand.
Auto-Standby handles this situation by partially unloading the compressor to a user-set level below the
required system pressure. To take advantage of this feature, the compressor must have a modulating
blow off valve.
Operational Characteristics
Auto-Standby control is identical to Auto-Offline control (detailed previously), until the situation
where the discharge check valve closes during blow off, under Blow Off System Pressure control. At
this point, Auto-Offline unloads the compressor.
However, in the Auto-Standby mode, the compressor is not allowed to unload. Instead, the controller
will continue to open the compressor blow off valve after the check valve has closed.
Blow off continues until the compressor discharge pressure drops to a user-set level below the System
Pressure setpoint.
The control setpoint for Auto-Standby is called the Standby Mode Offset, and it is a DP value.
For example: Where the system pressure setpoint is 115 psig, and the desired standby pressure is 105
psig, input a Standby Mode Offset of 10 psig.
The compressor continues to operate at the reduced standby pressure until the actual system pressure
drops to a level below the System Pressure setpoint. When this happens, the unit will fully load
through the inlet valve control loops.
C—11
Auto-Unload Control
In this Vantage control mode, inlet control is the same as Auto-Offline, but now only to the point
where the Maximum System Pressure setpoint is reached. Then, instead of blowing off, Auto-Unload
unloads the compressor. The compressor reloads as described above.
Auto-Unload Control Setpoints

Maximum Motor Load Setpoint: Prevents motor overload condition.
System Pressure Setpoint: Establishes initial pressure control point.
Surge Control Offset Line: Prevents compressor surging at minimum flow conditions.
System Pressure Offset: Sets an upper level for allowable system pressure.
Maximum Discharge Pressure: Prevents compressor surging at over-pressure conditions.
Auto-Unload Control Steps (see Figure C—3)

1. Compressor loads to achieve System Pressure setpoint (position 1).
2. When demand is low, the inlet valve throttles to the Minimum Flow line (position 2).
3. The inlet Minimum Flow control loop operates the compressor along the Min Flow control line
4. When the System Pressure Offset reaches setpoint (pos.3), the Auto-Unload control method
unloads the compressor by first fully opening the compressor discharge bypass valve, and then
closing the inlet valve to its minimum position (pos.4).
5. The compressor reloads when system pressure drops below the System Pressure setpoint.
Figure C—3: Auto-Unload Control Operation
C—12
Auto-Unload Control
The Auto-Unload control method is used for compressors that have a discrete (open/close) discharge
bypass valve (and not a modulating blow-off valve). Vantage handles this through the Auto-Unload
control method by unloading the compressor instead of blowing off.
This control method may also be useful when working with several compressors in the same air
header. It may be desirable to immediately unload and possibly turn off a small compressor before
allowing larger units to blow off.
Operational Characteristics
Auto-Unload control is identical to Auto-Offline control up to the point where the System Pressure
Offset value is reached. Then, instead of blowing off, the compressor immediately unloads.
In the unload process, the control system fully opens the compressor bypass valve then closes the inlet
valve to its minimum position. The controller automatically reloads the compressor when the actual
system air pressure falls below the System Pressure setpoint.
C—13
Compressor Safety Mechanisms

The Vantage Control System provides compressor protection by continuously monitoring vital functions
to ensure correct and safe operation of all compressor systems. Whenever operating conditions diverge
from predetermined safety parameters (the setpoints), the control system automatically triggers an
appropriate system response.
General Operating Principle

A variety of sensor devices are strategically located throughout the compressor’s various subsystems to
provide measurement of vital operating parameters. These measurements are monitored by the Van-
tage Control System, and the control panel provides a dynamic readout for data logging and trending,
adjustment, and diagnostic purposes. Whenever operating conditions reach a conspicuously divergent
or dangerous level, the control system triggers a control panel display message and the appropriate
safety response.
Sensors
A variety of sensor devices monitor the compressor process air, lubrication, electrical, and mechanical
components to ensure their correct operation.
· A current sensor located in the main drive motor terminal box measures the main motor
current.
· Electronic proximity devices, or vibration probes measure displacement (or vibration) of the
pinions at various standard and optional locations.
· Temperature sensors, or resistive temperature detectors (RTD’s) measure the oil temperature
in the compressor lubrication system, the third stage inlet air temperature, and other optional
locations.
· Pressure transducers measure the oil pressure in the compressor lubrication system as well as
the air system pressure and (when necessary) the compressor discharge air pressure.
Table C—1 lists the various standard and optional measurements taken by these sensor devices de-
scribed above.
Whenever a sensor device detects an operating condition that varies from predetermined parameters, a
compressor safety mechanism is activated.
C—14
Standard and Optional Measurements

Standard:
Main Drive Motor Current
System Air Pressure
Compressor Discharge Air Pressure
First Stage Vibration
Oil Pressure
Oil Temperature
Final Stage Inlet Air Temperature
Optional:
Second Stage Vibration
Third Stage Vibration (three stage units only)
Second Stage Inlet Air Temperature (three stage units only)
Inlet Air Filter Pressure Drop
Oil Filter Pressure Drop
Oil Reservoir Level
Compressor Discharge Air Temperature
Mass Flow Measurement
Multi-channel Temperature Monitor (motor bearing & stator windings)
Table C—1 Standard and Optional Measurements
Alarm and Trip Conditions

When operating conditions deviate from any of the preset setpoints, when a compressor or auxiliary
device fails, or when compressor performance becomes degraded, the control system will activate one
of two types of compressor safety mechanisms. The mechanism activated depends on the degree of
deviation, one being a warning signal and the other involving protective action.
The two compressor safety mechanisms are:
· Alarm. When an Alarm condition occurs, all compressor systems will continue operation. However,
the control panel display will record the Alarm to alert the operator of an operating condition that
requires some attention.
· Trip. When a Trip condition occurs, the Vantage Control System will initiate a complete compressor
shutdown in order to protect vital components. This will occur whenever one or more operating
conditions exceed the predetermined levels governing operating safety.
The Vantage Control System records all operating conditions current during both Trip and Alarm
conditions and shows them on the control panel display. As part of the control panel Diagnostics
function, the operator may also call up similar information for the four most recent Trip conditions or
compressor shutdowns. Trip messages (from most to least recent) are available for review.
C—15
Table C—2 shows Alarm and Trip levels for the Turbo Air 3000 Compressor. During an Alarm or Trip
condition, the control system will signal the control panel with that information. This will cause the
associated indicator light on the control panel to come on. Additionally, any associated auxiliary
warning device attached to the control system will also come on and/or sound.
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) 80 140 70 150
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
Compressor Bullgear Vibration (mils) - 2.5 - 3.0
Drive Motor Vibration (mils) - 2.5 - 3.0
Drive Motor Stator Temperature (ºF) - 330 - 340
Table C—2 ALARM and TRIP Setpoints (English Units)
ALARM and TRIP Setpoints (Metric Units)

ALARM TRIP
Condition Low High Low High
Standard:
Compressor Stage Vibration (µm) - 38 - 50
Oil Pressure (bar) 5.5 9.7 4.8 10.3
Oil Temperature (ºC) 20 57 15 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
Compressor Bullgear Vibration (µm) - 65 - 75
Drive Motor Vibration (µm) - 65 - 75
Drive Motor Stator Temperature (ºC) - 165 - 170
Table C—2 ALARM and TRIP Setpoints (Metric Units)
C—16
Glossary
Glossary
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.
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 Vantage 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 Vantage 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 maximum 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.
LED — the abbreviation for Light Emitting Diode.
Light Emitting Diode — a status indicating light on the Vantage 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.
MBOV — the abbreviation for Modulating Blow-Off Valve.
Minimum Amp Setting — a setpoint of the control system associated to the main drive motor
amperage draw that relates to the low-flow surge operating point of the compressor.
Mist Filter — a device that collects the oil vapor that is vented from the oil reservoir.
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.)
Glossary
“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 Vantage 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.
Surge — a compressor operating condition characterized by a momentary reversal of airflow back

through the compressor.
System Pressure — the pressure of the compressed air measured after the compressor check valve.
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 Vantage 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 Vantage 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

The Turbo Air® 3000

Cooper Turbocompressor, Inc.

About This Manual

About This Manual iii

Section One: Introduction

Section Two: Specifications

Section Three: The Control System

Section Four: Routine Operation

Section Five: Maintenance

Section Six: Troubleshooting

Section Seven: Parts and Service

Appendix B: The Lubrication System

Appendix C: Vantage Control System Logic

Appendix D: Control System Setpoints Adjustments

Appendix E: Control System Initialization

In this section, the reader will learn about:

¨ The Turbo Air 3000 Centrifugal

About Cooper Turbocompressor

Cooper Turbocompressor is ISO 9001 Certified.

To learn more, look us up on the Internet:

The Turbo Air 3000 Centrifugal Compressor

The Most Advanced

The Vantage Control System

Other Design Features

1. Horizontally split gearbox casing

Figure 1—2 The Turbo Air 3000 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

1. Loss of use of productive facilities or equipment.

In this section, the reader will learn about:

¨ General Compressor Specifications

¨ Compressor Lubricant Requirements

General Compressor Specifications

Compressor Rating (HP*) 400 500 600 700 800

Air Inlet 8” ANSI Pipe Condensate Drain ½” NPT **

Discharge Connection Load Limits

Bolt Diameter Torque Range

Cold Alignment Specifications for Main Drive Motors

General Compressor Specifications

Compressor Rating (hp) 400 500 600 700 800

Coupling Bolt Torque Values

General Compressor Specifications

Control Housing Mechanical Specifications

Vantage Electrical Specifications

Safety Approvals (optional)

Other Package Electrical Requirements

Compressor Lubricant Requirements

· Acceptable turbine oil

Compressor Oil Selection

· Refined from high-quality mineral oil stock.

Property Test Method Performance

Base Oil is to be refined from high-grade mineral oil stock.

Table 2—1 Cooper Turbocompressor Oil Specification

Other Oil Selection Considerations

· Use only Cooper Turbocompressor TurboBlendTM Lubricating Oil or a high-quality turbine

Inspection and Testing

· Color and Appearance

Other Required Lubricants

Motor Bearing Lubricants

Acceptable Motor Bearing Greases

Drive Coupling Grease

Inlet Guide Vane Assembly Drive Screw Grease