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Cooper Turbocompressor Turbo Air 3000 User Manual

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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

Table of Contents

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Cooper Turbocompressor Turbo Air 3000 Specifications

General IconGeneral
BrandCooper Turbocompressor
ModelTurbo Air 3000
CategoryAir Compressor
LanguageEnglish

Summary

Introduction

Cooper Turbocompressor Company Information

Details about Cooper Turbocompressor's history, innovation, and global leadership in centrifugal compressors.

The Turbo Air 3000 Centrifugal Compressor

Overview of the Turbo Air 3000 compressor, its design, and advanced components.

Safety Precautions and Labels

Essential safety guidelines and explanations of warning labels for safe operation.

Warranty and Liability

Details on compressor warranty coverage, limitations, and liability disclaimers.

Unauthorized Repair Policy

Information regarding the consequences of performing unauthorized repairs on the compressor.

Specifications Overview

General Compressor Specifications

Technical data including weights, connection sizes, bolt torques, and alignment specs.

Compressor Lubricant Requirements

Detailed information on required lubricants, oil selection, and performance standards.

The Control System

Vantage Control Panel and User Interface

Description of the control panel, its components, and the user interface module.

Control Panel Navigation Keys

Explanation of the function keys for operating the compressor and navigating screens.

Input and Operational Keys

Details on keys used for system interaction, value changes, and screen navigation.

Control System Practice Exercise

A hands-on guide to familiarize users with the Vantage control system.

Routine Operation Procedures

General Considerations for Routine Operation

Best practices for daily operation, record keeping, and maintenance.

Operating Data Record Maintenance

Guidelines for recording operational data for trend analysis.

Routine Startup (Local Control)

Step-by-step instructions for starting the compressor using local control.

Routine Shutdown (Local Control)

Step-by-step instructions for safely shutting down the compressor.

Adjusting System Pressure Set Point

Procedure for making minor adjustments to the system pressure set point.

Maintenance Procedures

General Maintenance Considerations

Importance of monitoring conditions and consulting specialists for service.

Daily Operator Inspection Checklist

A checklist for daily checks to ensure smooth compressor operation.

Scheduled Maintenance Procedures

Recommended intervals and tasks for routine scheduled maintenance.

Professional Service Inspection

Items requiring in-depth examination by an authorized representative.

Filter Maintenance Schedule and Procedures

Schedule and steps for inspecting and replacing various filters.

Compressor Lubrication Schedule and Procedures

Schedule and instructions for lubricating compressor components.

Additional Maintenance Procedures

Procedures for heat exchangers and discharge air check valves.

Troubleshooting Guide

General Troubleshooting Considerations

Overview of troubleshooting approach and compressor subsystems.

How to Use the Troubleshooting Guide

Guidance on navigating and utilizing troubleshooting charts effectively.

Requesting Assistance

Information on contacting authorized representatives for support.

Alarm and Trip Functions

Explanation of alarm/trip conditions and required operator response.

Drive Train Troubleshooting

Common issues and potential causes related to the drive train.

Control System Troubleshooting

Troubleshooting common problems encountered with the control system.

Air System Troubleshooting

Common issues and potential causes related to the air system.

Lubrication System Troubleshooting

Common issues and potential causes related to the lubrication system.

Parts and Service Information

Aftermarket Support Services

Overview of aftermarket support, including inspection, repair, and training.

Parts Ordering Procedure

Essential information required for ordering replacement parts.

Parts Availability and Returns

Information on part availability, substitutions, and the return goods policy.

Periodic Maintenance Parts Inventory

A recommended list of parts and supplies for routine maintenance.

Professional Inspection Parts Requirements

Parts and supplies necessary for in-depth professional inspections.

Control System Parts Identification

Identification and part numbers for control system components.

Lubrication System Parts Identification

Identification and part numbers for lubrication system components.

Main Drive Coupling Parts

Identification and part numbers for main drive coupling components.

Heat Exchanger Parts Identification

Identification and part numbers for heat exchanger components.

Air Piping Parts Identification

Identification and part numbers for air piping components.

Appendix A: Installation

General Installation Considerations

Importance of advance planning and preparation for a simplified installation process.

Installation Work Schedule Overview

Schedule outlining steps from site preparation to initial startup.

Required Labor, Supplies, Equipment, and Tools

Lists of necessary resources for compressor installation and maintenance.

Site Considerations for Installation

Factors for selecting and preparing an appropriate installation location.

Process Air Piping Installation Guidelines

Guidelines for designing and fabricating inlet, discharge, and bypass air piping.

Utility Piping Requirements

Requirements for external piping, tubing, and conduits for subsystems.

Electrical Conduit Installation

Guidelines for installing external electrical conduit for power supply.

Electrical Interface Requirements

Essential requirements for proper electrical connections of components.

Main Drive Motor Control Selection

Considerations for selecting motor starters and controls.

Receiving, Lifting, Moving, and Bolting Procedures

Procedures for safely handling, moving, and securing the compressor.

Preparing for Compressor Startup

Pre-startup inspections and verification steps before initial operation.

Preventing Potential Startup Problems

Common issues that may delay or complicate the installation and startup.

Pre-Startup Inspection Schedule

Service representative's verification tasks prior to initial compressor startup.

Initial Start-up Checklist

Sequence of steps for performing the initial compressor startup procedure.

Service Assistance Contact Information

Contact details for obtaining service assistance and support.

Appendix B: The Lubrication System

General Lubrication Considerations

Importance of adequate lubrication for compressor operation and system design.

Compressor Lubrication System Operation

Schematic illustration and principles of normal oil circulation.

Vantage Control of Compressor Lubrication

How the Vantage system monitors and controls the lubrication system.

Operational Guidelines for Lubrication

Recommendations for safe and efficient operation of the lubrication system.

Gearbox and Reservoir Venting System

Description of the ejector/filter system for preventing oil mist escape.

Optional Lubrication System Features

Description of optional features for enhanced lubrication system operation.

Appendix C: Vantage Control System Logic

General Considerations for Control System Logic

Overview of control methods and specialized information for technicians.

Compressor Control Methods Overview

Description of Auto-Offline, Auto-Standby, and Auto-Unload control methods.

Auto-Offline Control Mode

Detailed explanation of the Auto-Offline control logic and operation.

Auto-Standby Control Mode

Detailed explanation of the Auto-Standby control logic and operation.

Auto-Unload Control Mode

Detailed explanation of the Auto-Unload control logic and operation.

Compressor Safety Mechanisms

How sensors and the control system ensure compressor safety and protection.

Glossary of Terms