Cooper Turbocompressor Turbo Air 3000 Handbook
The Turbo Air® 3000
Contents
Centrifugal Compressor
with the V antage™ Control System
Compressor Handbook
Cooper Turbocompressor, Inc.
3101 Broadway P.O. Box 209
Buffalo, New Y ork 14225-0209 USA
AAEDR-H-059 Rev . 01
ECO-1910938 May 2003 FWG
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
ii
About This Manual
Contents
About This Manual
This manual contains the basic information necessary for using and maintaining the Turbo Air 3000
Oil Free Centrifugal Compressor, from the original startup and operation to inspection and servicing.
However, since installations may vary, these instructions may not cover all details or variations in the
equipment supplied or every question which may possibly arise during use.
If a question or situation develops which is not answered directly in this manual, contact an authorized
Cooper Turbocompressor sales or service representative for more information, or contact the factory
directly for specific answers and/or advice.
All operating personnel should become familiar with the contents of this manual before the compressor
is put into service. This is particularly important with regard to the safety precautions listed in the
Introduction and those included at relevant points of the procedures described in other sections of
this manual.
®
WARNING:
Read, be sure to clearly and completely understand, and then carefully follow all the
directions included in this manual. Failure to adhere to the guidelines and specific
instructions provided could cause equipment damage and/or serious personal injury
or death.
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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 T wo: Specifications
General Compressor Specifications 2— 3
Compressor Lubricant Requirements 2— 6
Section Three: The Control System
The Vantage Control Panel 3— 3
The Vantage User Interface 3— 4
Input or Operational Keys 3— 8
Pratice Exercise 3— 9
Section Four: Routine Operation
General Considerations 4— 3
The Operating Data Record 4— 3
Routine Startup 4— 5
Routine Shutdown 4— 6
Adjusting the System Pressure Setpoint 4— 7
Section Five: Maintenance
General Considerations 5— 3
Daily Inspection 5— 4
Scheduled Maintenance 5— 5
Professional Inspection 5— 6
Filter Maintenance 5— 7
Lubrication 5—11
Additional Maintenance Procedures 5—17
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
Section Six: Troubleshooting
General Considerations 6— 3
How to Use the Troubleshooting Guide 6— 4
How to Request Assistance 6— 5
Alarm and Trip Functions 6— 6
Drive T rain Troubleshooting 6— 8
Control System Troubleshooting 6—10
Air System Troubleshooting 6—12
Lubrication System T roubleshooting 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
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
Contents
Appendix F: Glossary
Contract Drawings
Supplemental Data
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
viii
Section One
Introduction
In this section, the reader will learn about:
¨ Cooper Turbocompressor
¨ The Turbo Air 3000 Centrifugal
Compressor
Introduction
¨ Safety Precautions
¨ Safety Labels
¨ Warranty
¨ Limitation on Liability
¨ Unauthorized Repair
1—1
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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 motivated 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 T urbocompressor is ISO 9001 Certified.
To learn more, look us up on the Internet:
Http//www.turbocompressor.com
Figure 1—1 The Buffalo, New Y ork, USA, Home Office and Centralized Facilities
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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. Superior pinion bearings designed for unlimited life and operation at any load. Non-contacting, nonwearing 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 backward-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 Controls.
The various control modes available provide optimal efficiency in even the most demanding applications, or, when necessary, maintain air system pressure at a uniform level.
NOTE: The T urbo Air 3000 Compressor package is not a complete, stand-alone compressed air
system. T o 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
T urbocompressor 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)
4
6
7
9
5
1
2
3
3
8
Figure 1—2 The T urbo Air 3000 Centrifugal Compressor
1—5
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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 T urbocompressor 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
Safety Labels
Introduction
WARNING
HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY
OR DEATH
Disconnect all power supplies, lock-out and display
signs before servicing equipment.
DANGER
AIR UNDER PRESSURE. WILL CAUSE SEVERE INJURY
OR DEATH
DO NOT operate the compressor at pressure in excess of
the nameplate rating.
Close the discharge block valve and relieve system of
pressure before removing any caps or plugs, or servicing
compressor.
DO NOT play with compressed air .
Wear eye protection when using compressed air .
CAUTION
ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE
DEATH.
All electrical enclosures and components must be installed
and grounded in accordance with the National Electric Code
and other local codes.
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
Safety Labels
WARNING
HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY.
Some surfaces of the compressor and motor have excessive
temperatures. T o 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 filtration 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 Departments.
1—8
Periodically check all safety devices for proper operation.
Safety Labels
Introduction
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 compressor 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
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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 judgment, 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 T urbocompressor’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 T urbocompressor’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 purchase price.
In no event shall Cooper Turbocompressor be liable for any special, indirect, incidental, or consequential damages of any character, including but not limited to:
1. Loss of use of productive facilities or equipment.
2. Lost profits, property damage, and/or expenses incurred in reliance on Cooper Turbocompressor’s
performance hereunder.
3. Lost production, whether suffered by the purchaser or any other third party.
Cooper T urbocompressor 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
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
1—12
Section Two
Specifications
In this section, the reader will learn about:
¨ General Compressor Specifications
¨ Compressor Lubricant Requirements
Specifications
2—1
The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
2—2
General Compressor Specifications
Installation Weights
Complete Package with Motor
Compressor Rating (HP*) 4 0 0 5 0 0 6 0 0 7 0 0 8 0 0
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.
Specifications
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 2 0 143-157 195-210
7/8 2 2 192-212 260-285
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
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
General Compressor Specifications
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) 4 0 0 50 0 6 0 0 7 0 0 8 0 0
Water Flow (gpm) 1 05 12 0 1 35 1 3 5 1 35
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°F15°C
System Operating Temperature 120°F50°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
General Compressor 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
V antage 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°F0° 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.
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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 procedures 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 T urbo 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 longerlasting 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 representative 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) AS TM D4172 £ 0.4 mm
Water Separability:
(54°C and 82°C) ASTM D 1 4 01 <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 T est:
Distilled Water ASTM D665A Pass
Synthetic Sea Water ASTM D665B Pass
Rotating Bomb Oxidation Test: ASTM D 22 72 > 400 minutes
Base Oil is to be refined from high-grade mineral oil stock.
T able 2—1 Cooper T urbocompressor Oil Specification
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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:
T o ensure optimum performance and to avoid possible compressor damage, always be
certain to follow the guidelines listed below.
· Use only Cooper T urbocompressor TurboBlendTM Lubricating Oil or a high-qualityturbine
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 lubrication 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.
T able 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.
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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.
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The Turbo Air 3000 Centrifugal Compressor Operator’s Manual
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 formulated to meet this very specific requirement.)
CAUTION:
Do not use a coupling grease with a K36 T est Rating above 0/24. Since other products may
cause premature wear and/or other damage, always use Cooper T urbocompressor 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.
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