Press the start button on the control panel. Page 58 Cooling water — as above. However, a few items should be checked periodically. Scheduled preventive maintenance and inspection is essential for continued optimum performance and long service life of the compressor. The following are general requirements and schedules for inspection and preventive maintenance.
Page 60 Disconnect and tie back all unused wires from terminal strips. Page 61 When using Techtrol Gold III, the lubricant must be changed every three years of after every 24, hours of use. For technical assistance, please call your local Ingersoll-Rand representative.
Main Driver Depending upon the customer's requirements, different drivers are used with the Centac compressor. Consult the driver manufacturer's literature provided in this manual to insure proper lubrication and maintenance procedures.
Page 63 7. Slide the panel filter into housing and latch all latches to the panel filter sides. All latches must be fastened to properly seal the final stage panel filter to the housing.
Replace the oil filter element s and inspect the housing for cleanliness. Continue with Casing Flush. See the Centac Clearance Setting Tool diagram on the next page. Install the clearance setting tool against the thrust bolt using one of the bearing cover bolt holes to support the other end. Page 68 Rinse screen in solvent to clean. Oil Filter A single line type oil filter is furnished as standard equipment on the Centac compressor. Some Centac compressors are furnished, as optional equipment, with a dual line type filter with a transfer valve.
Page 69 For more stubborn deposits, wire brushes or rods can be used. Mist Arrestor A reservoir mist arrestor is furnished as standard equipment on the Centac compressor.
Page 70 3. Inspect orifice seats for any corrosion or undesirable condition. Inspect the leverage system for freedom of movement. Similar maintenance care should be given to other optional styles of condensate removal systems. Page 71 Leaking or pinched oil line. Repair or replace oil line. Dirty oil filter. Replace with clean filter. Defective main oil pump. Repair or replace main oil pump. Page 72 Rotor assembly unbalance due to Contact Ingersoll-Rand service damaged aero parts. Repair or replacement and balance check required.
Induced vibration from driver. Balance motor rotor. Page 73 Reduction in motor efficiency. Consult motor manufacturer. Excessive load. Reduce load. High Drive Motor Low primary voltage. Restore voltage to specification. Amperage High load. Page 75 Ingersoll-Rand is ready. When you need results, Ingersoll-Rand produces. Ingersoll-Rand is committed to serving you.
When you need support for you Centac compressor, contact your local Ingersoll-Rand representative or call the factory direct. Page 76 This number will preclude material loss or processing delay at the factory. For emergency parts service call the factory direct at This manual is also suitable for: Centac c Print page 1 Print document 77 pages. Rename the bookmark. Delete bookmark? In both the "Full Load" and "MaxLoad" states, system pressure will be lower than setpoint pressure.
Unloading This state occurs when a valid Unload command is issued and will persist until the compressor reaches the Unloaded state. Coasting When a trip or any stop command is issued and the compressor is running, the motor will be de-energized and the compressor will begin to coast to a Stopped state.
This state will remain as long as the adjustable Coast Timer is in effect. At the end of the timer, the compressor will enter either the Ready or Not Ready state. Failure to set the Coast Timer for a period greater than or equal to the actual coasting time can result in compressor damage.
The standard configuration of the CMC has two components of the user interface. They are the OUI and the device plate. The key component of "easy to use" is that there are only twelve buttons to press on the OUI and four buttons, lights, and switches on the device plate. These keys in conjunction with the xpixel graphics display make up the user interface to the compressor.
When any of these keys are pressed the action will be logged in the event log. Key Name Acknowledge Function Silences the optional horn or acknowledges an alarm.
Reset Clears all trip latches. Required to be pressed after a trip condition to restart the compressor. Start Starts the compressor. Stop Stops the compressor. This button should be pressed instead of the E-Stop for normal operation. Load Engages Modulate or Autodual control mode. Unload Unloads the compressor. The page list is also circular. The current page for a folder is persistent.
Pressing this key steps among each of the sixteen contrast levels. When stepped to the sixteenth level, pressing the key again returns to the first contrast level. The Scroll mode is used to page through the event log. To deactivate the Scroll mode, press the Enter key. The display has three distinct regions as shown in the diagram below. The following are examples of the pop-up message in the event of an Alarm or Trip.
Figure 6. The tabbed folder with multiple pages metaphor has been used to reduce the complexity of a traversing at least ten pages of information. For the standard design, the maximum number of keys required to get to any of the ten pages is four.
This region is always visible from any folder and page combination. The Compressor Status Field messages are Trip, E-Stop emergency stop button pressed , RMT-Stop a remote stop has been pressed , Start Disabled an optional permissive start condition has not been satisfied , Alarm, Unload Selected the compressor will stay in "Unload" after "Starting" has been completed , and Load Selected the compressor will go to "Minload" after "Starting" has been completed.
This indication is provided to indicate to the operator that a remote location is in control of the compressor and the compressor may start, stop, load, unload, etc.
These three fields combine to provide the operator with the necessary information to create a cursory determination of the status of the compressor. When a more thorough determination is required, the operator can get additional detail by looking through the other pages in the system.
The Page Number indicates the current page for the current folder with the number of pages in the folder. The number of pages is given so that the user always knows where he is in the system. Once in this mode, the highlight will move from around the folder name to item to be changed. Use the Right and Left arrow keys to move among the changeable items and the Up and Down arrow keys to change the value of the item. When changes are complete, press the Enter key again to return to Navigation mode.
The number of pages in this folder is at least four; but could be more for two stage machines with special analog options purchased, or for compressors with three stages or more.
The System Pressure and Pressure Setpoint are in units as defined by the Settings page, Motor Current is in Amps and valve positions are in percent open. Pressure Setpoint is always editable while the Inlet and Bypass Valve positions are edit enabled when in the Manual mode only.
These are the only editable settings in any folder other than the Settings Folder. If additional analog inputs have been purchased or more stages exist as standard, it is likely that an additional page or pages will be added. The units are as defined by the Settings page. There are no changeable setpoints on this page. The Digital Input page shows the current state of the digital discrete inputs for the system. The number of inputs will vary depending upon the number of optional inputs purchased.
For example, a check mark in the "E-Stop Pressed" boxed means that the Emergency Stop push button has been pressed. It is possible to have multiple Digital Input pages. The number of outputs will vary depending upon the number of optional items purchased.
It is possible to have multiple Digital Output pages. The User is always within two keystrokes of all operating parameters. This page of the INFO folder shows the phone number to call for parts or service.
This is the number of the local Ingersoll-Rand representative. The number can be changed only by use of Service Tool. These parts may also be located in the compressor bill of materials. In the event that the part numbers are not available, such as retrofitting the CMC on a competitive machine, this screen may not be visible.
Pressing the Enter key to initiate Scroll Mode allows access to the entire instructions. Scroll Mode is indicated by the reverse video of a slide bar. Each Down Arrow press displays the next eight lines of instructions. An Up Arrow press will display the previous eight lines of instructions. The slide bar on the page indicates current location within the text. If a Trip occurs while on this page, the system will send the display to the event log page. The OUI key map will be the default page on power up.
The keys are labeled in English and the local language, depending upon the current language selected. Each "event" has a date and time stamp. First-out indication for all Alarms and Trips is satisfied by this log. Any time an Alarm or Trip is indicated on the Status Bar, the detail for that fault is included here.
The event labeled as "1" is the newest event and "7" is the oldest event. Once the list is full, each new event knocks off the last event. Pressing the Enter key to initiate Scroll Mode allows access to events 17 through Scroll Mode is indicated by the reverse video of the event numbers. Each Down Arrow press displays the next seven events. An Up Arrow press will display the previous seven events. Any time a Trip occurs, the system will send the display to the first seven events.
Acknowledge Location An Acknowledge command has been issued from Location. Compressor Started The compressor has started. Discrete Surge A discrete surge switch has detected a surge. Edit-x Day The Day value for the Date field has been edited from location x. Edit-x Month The Month value for the Date field has been edited from location x.
Edit-x Sensitivity The Surge Sensitivity value has been edited from location x. Edit-x Time The Time value has been edited from location x. Edit-x Year The Year value for the Date field has been edited from location x. E-Stop pressed Emergency Stop push button has been pressed. Load Location A Load command has been issued from network communications. Loss of Motor Current Motor current feedback was lost while running. Starting Fail Driver feedback was not received after a Start command was issued.
Starter Failure Feedback was not received from the starter after a Start command was issued. Reset Location A Reset command has been issued from Location.
Start Location A Start command has been issued from Location. Starter Failure Starter feedback was not received after a Start command was issued. Stop Location A Stop command has been issued from Location. Surge The controller has detected a Surge. Surge Unload Alarm The alarm condition when the compressor has unloaded as a result of multiple surges.
Unload Location An Unload command has been issued from Location. Table 6. NOTE The next page shows the hour meters and number of starts. Power On Hours is the time that the panel power has been on. The Running Hours is the amount of time that the compressor has been operating between each start and stop sequence.
The Loaded Hours is the amount of time that the compressor has been running and not running unloaded. It can also be defined as the number of hours that the inlet valve is not in the Inlet Unload Position. The Number of Compressor Starts is self explanatory.
Most electric motors are only rated for two cold starts or one hot start per hour. It is the operator's responsibility not to exceed the electric motor's limitation. The control system allows the compressor to be started when the compressor is ready, not the motor. This will be used by field personnel for quick reference to determine if newer software is available.
In this folder, the User will enter performance and control operating parameters, analog health monitoring settings for Alarm and Trip conditions, control mode selection, setpoint changes, password, and user interface language. This folder is the primary location for editing setpoints. The Password takes four numbers. If the Password is entered properly, Changes will be enabled a check will be in the box ; otherwise, they are disabled. This enabling and disabling applies to all changeable setpoints except, Pressure Setpoint, Throttle Limit, language selection and the Password, these items are always modifiable.
Each control system is shipped with two languages and units of measure combinations. The first set is for the English language, pressures in units of PSIG, temperatures in units of degrees F and vibrations in units of mils. The other set will be localized for the customer. The default alternate language is English with Metric units. Language support will be provided as standard for English, all European languages required for the CE Mark, and Chinese. This system has the ability for any language because of the graphics display.
Asian character support will require additional screens because these characters require four times the number of pixels. There are no limitations on the units of measure. Each analog input has its own scaling factor and offset. The Date is set with three separate values 1 Year, including century 2 Month and 3 Day. The Time is also set with three values 1 Hour, 2 Minutes and 3 Seconds.
Failure to set this properly could result in damage to the motor. MinLoad Control Setpoint is the actual value used to determine when the bypass valve begins constant pressure control in lieu of the inlet valve.
This value equals the MinLoad User Setpoint plus the number of surges times the index increment value. The indication that it has been reset will be in the event log. The event message "MinLoad Reset" will be displayed. When disabled, the compressor will Unload on any surge condition. The Surge Sensitivity setting has a range from one 1 to ten 10 where one is not sensitive a "soft" surge condition could exist without being identified and ten is very sensitive a "soft" surge condition would be identified.
We ship the machine with a default value of nine 9. This setting will pick up most surge conditions. You should periodically reset the MinLoad Control Setpoint to prevent excessive air bypass. This gives the controller precise control for modeling the air system over the entire operating range of the compressor.
With this release, the Derivative constant has been added to give even more capability to match the control system to the air system. However, we recommend that this value remain at zero unless you have full understanding of how this parameter works.
Please change this value with caution. This selection process is performed with the radio button selector. To change the selection, press the Up or Down arrow key. Checking the Manual checkbox enables manual valve control. In this mode, the inlet valve may be stroked when the compressor is not running, and the bypass valve can be stroked at any time.
If a surge condition occurs while manually controlling these valves, the CMC will automatically take over the valves. Typically, this time includes the starter transition time Y-D time. When this timer expires, the prelube pump will turn off and the compressor is enabled for loading. Coasting Timer is the length of time that it takes for the driver to stop rotating.
When checked, Motor Failure Trip Enable tests that the zero amp motor current has been reached after a start command has been initiated and that motor current is not lost while the compressor is running. Uncheck this box for dry run conditions. The Inlet Unload Position is the position of the inlet valve when in the unload state.
Setpoint Ramp Rate is used to prevent system pressure overshoot during compressor loading. The number of inputs varies depending upon the number of compression stages and optional inputs.
Additional pages will be added as needed after this page. All line items are changeable for the Alarm and Trip setpoints. This push button is used to initiate a stop in the case of an emergency. The following figure will be referenced in the procedures. The ASF is found by obtaining the motor service factor from the motor nameplate and selecting the adjustment factor from the table below. The motor full load amps is found on the motor nameplate. If system demand is below this throttle point, the compressor must bypass air or unload.
If flow were allowed to go below MinLoad, the machine would eventually hit the surge line and surge. By stopping inlet valve throttling at MinLoad the machine is kept out of surge. To find the MinLoad setting, the machine is run into the surge line, and the value of load amps, kilowatts, SCFM at surge is recorded.
The recorded value is then incremented by five percent and set as the value for MinLoad. Before continuing this procedure, verify the following: - The inlet and bypass control valves have been calibrated. Set initial MinLoad estimates. Preset the manual bypass valve position to Load the compressor by pressing the Load Key. Find the throttled surge point. It the system does not stay at MinLoad, slightly decrement the valve position to force the machine to throttle to MinLoad.
Increase MinLoad by five percent. Exit MinLoad editing by pressing the Enter Key. Unload the machine. Disable manual valve control by unchecking the manual check box.
To set the surge sensor the machine is forced to surge by running the machine at MinLoad and the MinLoad setpoint is dropped until the machine audibly surges. The process is repeated until the correct setting is found. Before continuing this procedure, verify the following: - The plant can tolerate a pressure disturbance when the machine surges. Set the initial Surge Sensitivity setting to 9. Press the Load Key. Run the compressor at MinLoad at pressure. The machine can be forced to MinLoad and pressure by either: - Running the plant at a higher pressure than pressure setpoint.
Typically the machine will make a puffing or popping noise upon surge, this is your indication surge has occurred. Press the Unload Key. Determine if Surge was recorded. If the message Surge Unload is displayed surge was recorded, if the message is not displayed surge was not recorded.
Check the Surge Sensitivity setting. Surge Sensor too sensitive. Surge Sensor not sensitive enough. Repeat the procedure until the Surge Sensitivity setting is found which just catches a surge but does not miss a surge.
Restore all values but Surge Sensitivity. When the machine is running above the MinLoad point and below the MaxLoad point, pressure is regulated with the Inlet Valve Pressure control loop. When the machine is running at the MinLoad point, pressure is regulated with the Bypass Valve Pressure control loop and motor current is regulated with the Inlet Valve MinLoad control loop.
For a definition of the parameters and their effect on stability, refer to the section titled "How does Constant Pressure Modulation Work. The valves should be adjusted to physically correspond with the valve positions displayed on the OUI.
Stop the compressor. Performing this procedure while the compressor is operating may cause serious damage. NOTE 2. On the OUI select the Settings Folder and enable manual valve control by highlighting the manual check box. When Manual is enabled, both control valves can be positioned while stopped, while only the Bypass Valve can be positioned when Loaded.
NOTE 5. Use the horizontal navigation keys to select the valve requiring positioning. Use the vertical arrows to increment and decrement the valve position sent to the valve. For the Inlet and Bypass Valves, the displayed position corresponds to percent open. NOTE 8. Disable manual valve control by blanking the manual check box. The procedure for tuning Autodual requires the setting of the following variables: 6. This position is found by running the machine at MinLoad and monitoring the System and Discharge pressures.
Example: Given the following conditions the Unload Point would be set at Typically, when the check valve closes, system demand requires the check valve to open again soon thereafter due to the demand being on the verge of requiring the compressor. For this reason, the timer is used to inhibit Unload until demand has consistently remained low. Run the compressor at MinLoad by either: - Running the plant at a higher pressure than pressure setpoint. Determine delay time. This value should be set according to the customer's minimum acceptable system pressure.
This procedure requires the Inlet Unload Position to have been set. Initially set the Start Time to 25 Seconds. Caution: Damage to the starter contacts could result if starter transition occurs before the compressor is up to full speed. On the OUI record the time and press the start button. Wait for the compressor to stop accelerating and again record the time.
Calculate the difference between the two values and enter as the Start Time. Divide the primary by the secondary and enter the value as the CT Ratio. Example: CT is printed with , the value entered is For a description of the Unloaded state refer to the section titled "Unload".
If the inlet valve is a butterfly type, enter an initial value for Inlet Unload Position of If the inlet valve is a inlet guide vane type, enter an initial value for Inlet Unload Position of 5. Start the machine. If during startup the motor trips on overload, is drawing what is considered excessive amperage or sounds labored, stop the machine and decrease the Unload Position by 2.
Run the machine in the Unloaded state and monitor the first stage pressure. Adjust the Unload Position to achieve 1 PSIG on the first stage discharge, or until a positive pressure is felt at the first stage trap bypass. The setting should be set as high as possible without creating excessive overshoot when the machine enters the system. Determine overshoot. If overshoot is excessive. If overshoot is satisfactory and time to load is excessive.
If overshoot is satisfactory and time to load is satisfactory the Setpoint Ramp Rate is correct. These values determine when the controller will indicate an alarm or trip condition. He will provide a detailed technical reference manual for the communication.
Customers may want to communicate to the CMC control systems for remote compressor control and monitoring. This communication capability provides for flexibility in the customer's compressed air operation through remote start and stop, data gathering for preventative maintenance, and incorporation into plant-wide control system.
This requires hardware for the control panel, and a communications device with the appropriate driver software to perform the desired panel functions. The customer or his representative must write system software to suit his individual needs for remote control and monitoring.
Since the customer writes this interface, the system can be as flexible as the customer desires. Both provide energy management through load sharing and reduction of air bypass by using a minimum amount of energy to meet the system demand. Both ASC and ASM provide a window into the compressor room by making the raw data from compressors and other equipment available to plant operators and managers in formats that are easy to understand. In the descriptions that follow, the PC and PLC serial devices are not specific to manufacturers or operating systems.
Most of the following methodologies are currently available; but please be aware, other possible configurations can exist. The interface software allows a specific serial device and operating system to transmit, receive and interpret data from a CMC control system. The application software tells the CMC control system what to do; for example, start compressor when ready, stop compressor after midnight and retrieve the current data and save to a disk file.
Currently there are hundreds of different serial devices using different operating systems and languages in the industrial equipment world. Therefore, the practicality of having an interface for many systems is limited. Custom interfaces must be written as required by the hardware and operating system used.
The capabilities of the hardware and the imagination of the developer only limit the application software. For example, one developer may have two compressors.
In this application the developer wants a screen to display the compressor interstage pressure and temperatures for both machines with various other compressor data. A second developer has five compressors. He also wants to display the same data, but this time for all five machines. The only way this is done is through changing the application software custom modification.
The developer may write functions to read and display data, log that data to some magnetic media for storage, change compressor set points, sequence the compressors for efficient operation and network additional devices, such as pumps, dryers, etc. All of these functions require specially written application software for the intended use. In order to communicate over other types of networks, a network adapter must be used. The information presented in the following sections does not include MODBUS protocol details like framing messages and calculating checksums.
This can be obtained through the Internet at "www. Unless specified otherwise, numerical values such as addresses, codes, or data are expressed as decimal values in the text of this section. They are expressed as hexadecimal values in the message fields of the examples.
NOTE Figure 6. The user must specify the serial port communication parameters baud rate, parity mode, etc. The following check list is to prevent oversights which could delay start-up of the unit and additional expense in correcting oversights.
Refer to the Driver Manufacturer's instructions. Personnel unfamiliar with the compressor package should not start, operate or tamper with the equipment. Only fully trained personnel should be allowed to start and operate this compressor. The following procedure is a guideline for the fully trained operator.
Remove such device before start up. The locking device must be removed only by Ingersoll-Rand qualified personnel. Compressors with motor directly flanged to the compressor does not need alignment. If further on site alignment is needed before start up, please refer to Ingersoll-Rand customer service. CAUTION If the compressor is driven by a turbine, please refer to the manufacturer manual for all necessary information necessary for start up preparation.
Change filter elements. Low surge. See continual surging below. Greater demand than realized. Repair All air leaks. Turn off unnecessary demands.
High Low oil temperature. Allow warm-up period for Vibration oil. Driver to compressor Check and correct misalignment. Worn coupling or spacer. Rotor assembly unbalance due Contact Ingersoll-Rand to foreign matter build up. Cleaning and balance Rotor assembly unbalance due check required.
Repair or replacement and balance check required. Induced vibration from driver. Balance motor rotor. Modulate or Auto-Dual operating mode. Low set point on pressure Adjust controller to desired Controller. Bypass valve not closed or Correct improper operation inlet valve not open. High Drive Low primary voltage. Restore voltage to Motor specification. Amperage High load Reduce load. Open block valve. Surge Dirty inlet filter. Pumping Improper adjustment of Adjust throttle limit.
High inter stage air Establish correct water temperature. Higher water temperature Reduce the cooling water than realized. Worn or fouled aerodynamic Contact Ingersoll-Rand parts. Power realized. Consult power company. Check power source. Reduction in motor efficiency. Consult motor Excessive load. Open navigation menu. Close suggestions Search Search. User Settings. Skip carousel. Carousel Previous. Carousel Next.
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