Ingersoll-Rand CENTAC Series Bedienungsanleitung

INGERSOLL-RAND

AIR COMPRESSORS

CENTAC

Troubleshooting Guide

CENTAC TROUBLESHOOTING GUIDE

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-Dec-94

THE CONTENTS OF THIS MANUAL ARE PROVIDED “AS IS” AND WITHOUT ANY IMPLIED

WARRANTIES WHATSOEVER.

Ingersoll-Rand air compressors are not designed, intended, or approved for breathing air

applications. Ingersoll-Rand does not approve specialized equipment for breathing air

applications and assumes no responsibility or liability for compressors used for breathing air

service.

CENTAC TROUBLESHOOTING GUIDE

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-dec-94

Table of Contents

Surge______________________________________________________________________1

Low Seal Air Pressure________________________________________________________2

Low System Air Pressure _____________________________________________________3

High Vibration ______________________________________________________________4

Low Control Air Pressure _____________________________________________________5

Low Instrument Air Pressure __________________________________________________5

Failure to Start ______________________________________________________________6

No Control Power ___________________________________________________________7

Failure to Load______________________________________________________________7

Low Oil Pressure ____________________________________________________________8

High Oil Temperature ________________________________________________________9

High Air Temperature _______________________________________________________10

Common Conversions and Information ________________________________________11

1. Temperature __________________________________________________________11

2. Pressure – gauge______________________________________________________11

2. Pressure – gauge, continued ____________________________________________12

3. Length_______________________________________________________________12

4. Flow_________________________________________________________________13

5. Volume ______________________________________________________________13

6. Electrical_____________________________________________________________14

6. Electrical, continued ___________________________________________________15

7. Vibration _____________________________________________________________16

8. Water Quality Requirements_____________________________________________17

CENTAC TROUBLESHOOTING GUIDE 1

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-dec-94

Surge

Cause Solution

1. Dirty inlet air filter. Replace filter.

2. Too small inlet pipe (remote-mounted

air filter). Replace pipe.

3. High interstage air temperatures. Investigate. Check to see what is

necessary to lower air temperatures.

Check water temperature, water flow,

water pressure, etc.

4. Increase in water temperature. Investigate. Check to see if it is possible

to lower water temperature.

5. Increase in inlet air temperature. Lower setpoint.

6. Setpoint higher than design discharge

pressure of compressor. Lower setpoint.

7. Defective system pressure controller. Adjust or replace.

8. Too low CLL or LLR (throttle surge). Increase CLL or LLR setting.

9. Too low P1, PR3, or mechanical stop

adjustment (unloaded surge). Increase P1, PR3 or adjust mechanical

stop.

10. Improper calibration of valve I/P,

positioner, or actuator. Calibrate as necessary.

11. Defective bypass valve. Repair or replace.

12. Restriction in customer's system. Investigate. Take necessary steps to

correct restriction. Check for closed block

valve or excessive dryer pressure drop.

13. Restricted air flow through air coolers. Clean air coolers.

14. Dirt build-up on impeller vanes. Clean impeller.

15. Blockage of diffuser air passage. Clean diffuser.

16. Improper wheel clearance. Reset clearance.

17. Worn or damaged impeller. Replace.

18. Butterfly valve pin broken. Replace pin.

19. Discharge check valve hanging up. Repair or replace.

2CENTAC TROUBLESHOOTING GUIDE

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-Dec-94

Low Seal Air Pressure

Cause Solution

1. Seal air regulator malfunctioning. Adjust, clean, or replace regulator.

2. Low instrument air pressure. Increase instrument air pressure.

3. Damaged seal air line. Replace.

4. Leaking fitting. Replace or tighten.

5. Leaking seals. Replace.

6. Seal air bleed valve open too far. Adjust.

7. Instrument air filter dirty. Clean or replace element.

8. Excessive clearance between pinion

and seal. Investigate. Replace seal and/or pinion.

CENTAC TROUBLESHOOTING GUIDE 3

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-dec-94

Low System Air Pressure

Cause Solution

1. Incorrect setpoint. Adjust.

2. Incorrect valve calibration. Restroke valves.

3. Bad controller. Repair or replace.

4. Dirty inlet filter. Replace filter elements.

5. Compressor operating unloaded. Switch selector switch to load.

6. System demand greater than

compressor capacity. Check for excessive air usage like open

valves, leaking fittings, etc., and correct.

Start additional compressor. Recommend

that customer purchase another Centac if

additional capacity is required.

7. Compressor block valve closed. Open valve.

8. Incorrect controls calibration. Adjust controls.

9. Discharge check valve sticking. Repair or replace.

10. System air pressure sensing point in

wrong location. Relocate control air connection

11. Excessive pressure differential across

air dryer. Investigate and correct.

12. Too low CLH setting. Increase setting (Do not exceed

FLA+SF).

13. Leaking bypass valve. Investigate and correct. Replace seat;

free up sticking valve.

14. Bypass valve stays open; inlet valve

functions normally. Lower CLL to activate bypass valve on

MP3 panel. Ensure 2TR is operating

properly on Electro-Pneumatic panel.

4CENTAC TROUBLESHOOTING GUIDE

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-Dec-94

High Vibration

Cause Solution

1. Low oil temperature. Increase oil temperature by adjusting oil

heater thermostat. Close cooling water

valves to oil cooler. Circulate oil.

2. High oil pressure. Reduce pressure. Adjust main oil pump

pressure relief valve with oil at operating

temperature.

3. Oil not draining properly from

bearings. Investigate and correct. Check for

restriction, improper venting, too high oil

level.

4. Incorrect coupling alignment. Realign coupling.

5. Worn coupling. Replace.

6. Excessive grease in coupling. Remove excessive grease.

7. Bad bullgear or intermediate gear

bearings. Replace.

8. Unbalanced motor rotor. Have motor rotor balanced.

9. Bad motor bearings. Replace.

10. Worn rotor assembly parts. Replace rotor assembly or necessary

parts.

11. Excessive build-up on impellers. Clean and balance rotor assembly.

12. Excessive pipe strain. Remove pipe strain.

13. Incorrect type of oil. Replace with correct oil.

14. Bad rotor assembly bearings or seals. Replace.

15. Excessive moisture carryover. Investigate and correct. Check for

restriction in condensate drainage

system.

16. Inadequate oil supply to plain

bearing. Investigate and correct. Ensure oil supply

groove in plain bearing shell is aligned

properly with oil supply hole through

casing.

CENTAC TROUBLESHOOTING GUIDE 5

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-dec-94

Low Control Air Pressure

Cause Solution

1. Too small control air line. Replace with larger diameter pipe.

2. Moisture in control air line. Remove moisture.

Provide permanent method for moisture

removal.

3. Sensing control air pressure from

wrong location. Change location of sensing pressure.

4. Leaking fittings or damaged pipe. Repair or replace.

5. Closed C.A. valve. Open valve.

Low Instrument Air Pressure

Cause Solution

1. Instrument air line too small. Replace with a larger pipe.

2. Instrument air dryer malfunctioning. Repair or replace.

3. Instrument air valve closed. Open valve.

4. Instrument air supply pressure below

recommended pressure. Increase supply pressure. Obtain a

different air source of adequate pressure.

5. Dirty I.A. filter. Clean or replace.

6. I.A. filter wrong size. Replace.

7. Leaking fittings or damaged pipe. Repair or replace.

6CENTAC TROUBLESHOOTING GUIDE

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-Dec-94

Failure to Start

Cause Solution

1. No power to motor starter. Energize power.

2. Blown fuse. Replace blown fuse.

3. STOP button pushed in.Pull out STOP button.

4. Overloads tripped. Reset overloads.

(If trip occurs do not reset find cause of

trip)

5. Control wiring incorrect. Investigate and correct.

6. Trips at transition. Mechanical linkage out of adjustment.

Bad 2M contactor. Replace or repair

contactor.

7. Interlocks not satisfied. Investigate and correct. Adjust

mechanical interlocks.

8. Bad motor starter. Repair or replace.

9. Loose or corroded wiring. Tighten and/or clean as necessary.

10. Control relay defective. Replace.

11. Low voltage. Investigate. Increase voltage supply.

Increase wire size. Increase breaker size.

12. Control circuit not grounded properly. Ground neutral at transformer. Check

wiring.

13. Wiring to remote starter incorrect. Investigate and correct.

CENTAC TROUBLESHOOTING GUIDE 7

CST-TP0007

1994 Ingersoll-Rand Company

Date of issue: January, 1999 Supersedes: 16-dec-94

No Control Power

Cause Solution

1. POWER ON selector switch OFF. Turn POWER ON switch to ON.

2. Blown fuse. Replace fuse.

3. Bad control power transformer. Replace.

4. Control power transformer wired

incorrectly. Correct transformer wiring.

Failure to Load

Cause Solution

1. LOAD selector switch in the wrong

position. Turn switch to LOAD.

2. Inlet valve stuck. Investigate and correct.

3. Controller setpoint too low. Adjust.

4. No control air signal. Investigate and correct. Check for closed

valve.

5. Surge sensor tripped. Adjust or replace.

6. Bypass valve will not close. Investigate and correct.

7. No power air to inlet or bypass valve. Investigate. Open power air shutoff valve.

8. Valve actuator or positioner

malfunctioning. Repair or replace.

9. REMOTE/LOCAL switch for CEM in

wrong position. Turn to REMOTE for CEM operation.

10. Incorrect CLL setting. Reset to correct value.

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