CENTAC

Troubleshooting Guide

INGERSOLL-RAND
AIR COMPRESSORS
CENTAC TROUBLESHOOTING GUIDE

Copyright Notice

Copyright 1996-1997 Ingersoll-Rand Company

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.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE

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

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
CENTAC TROUBLESHOOTING GUIDE 1

Surge
Cause Solution

1. Dirty inlet air filter. Replace filter.

2. Too small inlet pipe (remote-mounted Replace pipe.

air filter).

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 Lower setpoint.

pressure of compressor.

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

10. Improper calibration of valve I/P, Calibrate as necessary.

positioner, or actuator.

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.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
2 CENTAC TROUBLESHOOTING GUIDE

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 Investigate. Replace seal and/or pinion.

and seal.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE
Low System Air Pressure
Cause
1. Incorrect setpoint.
2. Incorrect valve calibration.
3. Bad controller.
4. Dirty inlet filter.
5. Compressor operating unloaded.
6. System demand greater than
compressor capacity.
7. Compressor block valve closed.
8. Incorrect controls calibration.
9. Discharge check valve sticking.
10. System air pressure sensing point in
wrong location.
11. Excessive pressure differential across
air dryer.
12. Too low CLH setting.
13. Leaking bypass valve.
14. Bypass valve stays open; inlet valve
functions normally.
Date of issue: January, 1999 Supersedes: 16-dec-94
3
Solution
Adjust.
Restroke valves.
Repair or replace.
Replace filter elements.
Switch selector switch to load.
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.
Open valve.
Adjust controls.
Repair or replace.
Relocate control air connection
Investigate and correct.
Increase setting (Do not exceed
FLA+SF).
Investigate and correct. Replace seat;
free up sticking valve.
Lower CLL to activate bypass valve on
MP3 panel. Ensure 2TR is operating
properly on Electro-Pneumatic panel.
CST-TP0007
1994 Ingersoll-Rand Company
4 CENTAC TROUBLESHOOTING GUIDE

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 Investigate and correct. Check for
bearings. 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 Replace.

bearings.

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 Investigate and correct. Ensure oil supply
bearing. groove in plain bearing shell is aligned
properly with oil supply hole through
casing.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 5

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 Change location of sensing pressure.

wrong location.

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 Increase supply pressure. Obtain a

recommended pressure. 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.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
6 CENTAC TROUBLESHOOTING GUIDE

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.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 7

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 Correct transformer wiring.

incorrectly.

Failure to Load
Cause Solution

1. LOAD selector switch in the wrong Turn switch to LOAD.

position.

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 Repair or replace.

malfunctioning.

9. REMOTE/LOCAL switch for CEM in Turn to REMOTE for CEM operation.

wrong position.

10. Incorrect CLL setting. Reset to correct value.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
8 CENTAC TROUBLESHOOTING GUIDE

Low Oil Pressure

Cause Solution

1. Incorrect relief valve adjustment. Adjust main oil relief valve to obtain 25-27
psi at correct operating oil temperature.

2. Dirty oil filter. Replace.

3. Leaking check valve. Replace.

4. Defective main oil pump. Repair or replace.

5. Leaking bullgear cover seal. Remove cover and install new silicone
sealant around oil supply groove.

6. Leaking or pinched suction line. Repair or replace.

7. Low oil level. Ensure 1-1/2" - 2" oil cover (minimum)

above top of suction screens.

8. Excessive gerotor axial clearance. Tighten axial clearance.

9. Wrong prelube pump motor. Obtain correct prelube pump motor.

10. Wrong size pump. Install correct pump.

11. Too big prime line. Install smaller prime line or remove
entirely.

12. Suction and discharge lines reversed. Correct.

13. Unloaded oil pressure low. Increase P1 value.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 9

High Oil Temperature

Cause Solution

1. Inadequate water flow. Provide adequate water flow to the oil

cooler.

2. High water temperature. Lower water temperature; use a cooler

water source.

3. Bad AMOT valve. Replace.

4. Water control valve thermostat out of Calibrate controller.

calibration.

5. Dirty oil cooler on water side. Clean water side of oil cooler.

6. Incorrect oil. Check oil specification against I-R oil

requirements; install correct oil.

7. Water/glycol mixture greater than Adjust mixture to ensure the glycol is not
50/50. greater than 50%.

8. Water temperature supply higher than Install larger oil cooler or additional
oil cooler design. cooler.

9. Heat exchanger radiating fins dirty. Clean fins.

10. Incorrect number of water passes. Investigate. Orient return bonnett

correctly; replace bonnett gasket if
bypassing; install cooler with more
passes.

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
10
High Air Temperature
Cause
1. Inadequate water flow.
2. High water temperature.
3. Water control valve thermostat out of
calibration.
4. Plugged water passages or scale on
the tubes.
5. Water flow bypassing air cooler.
6. Water/glycol mixture greater than
50/50.
7. Heat exchanger radiating fins dirty.
8. Water flows backward. Cold water
inlet on cooler hot air inlet side is
backwards flow.
9. Air cooler oriented incorrectly.
CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE
Solution
Provide adequate water flow to the air
cooler; adjust water flow to the air cooler.
Lower water temperature; use a cooler
water source.
Calibrate controller.
Clean water side of air cooler.
Investigate and correct. Replace waffle
gasket if it is missing or damaged. Reglue
it if it is loose.
If shroud is loose, reinstall with correct
pop rivets. Never use aluminum pop
rivets.
Adjust mixture to ensure the glycol is not
greater than 50%.
Clean fins.
Investigate. Repipe if water piping is
backwards; switch backflush valve to
correct position.
Remove air cooler and rotate to align the
water ports correctly with the water
connections of the casing.
CENTAC TROUBLESHOOTING GUIDE 11

Common Conversions and Information

1. Temperature

Fahrenheit to Celsius C = 5/9 (F-32)

Celsius to Fahrenheit F = 9/5C + 32

2. Pressure gauge

PSI to Atmosphere PSI X 0.06805

PSI to inches of H2O at 68F PSI X 27.73
PSI to inches of mercury (in Hg) at 0C PSI X 2.036
PSI to kPa PSI X 6.8948
2
PSI to Kg/cm PSI X 0.07031
2 2
Kg/cm to Atmosphere Kg/cm X 0.9678
2 2
Kg/cm to bars Kg/cm X 0.98066
2 2
Kg/cm to inches of mercury (in Hg) at 0C Kg/cm X 28.96
2 2
Kg/cm to kPa Kg/cm X 98.066
2 2
Kg/cm to PSI Kg/cm X 14.223
kPa to PSI kPa X 0.145
bars to PSI bars X 14.504
inches of H2O at 68F to inches of mercury (in Hg) at 0C in H2O X 0.07342
inches of water at 68F to psi in H2O X 0.03606
inches of water at 68F to kPa in H2O X 0.2487
2
inches of water at 68F to Kg/ cm in H2O X 0.002535
inches of water at 68F to bar in H2O X 0.002487
inches of water at 68F to standard atmosphere (atm) in H2O X 0.002454
inches of mercury at 0C to inches of water at 68F in Hg X 13.62
inches of mercury at 0C to psi in Hg X 0.03606
inches of mercury at 0C to kPa in Hg X 3.3864

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
12 CENTAC TROUBLESHOOTING GUIDE

2. Pressure gauge, continued

2
inches of mercury at 0C to Kg/cm in Hg X 0.034532
inches of mercury at 0C to bar in Hg X 0.033864
inches of mercury at 0C to standard atmospheres (atm) in Hg X 0.03342

atmosphere (standard) to bar atm X 1.01325

atmosphere (standard) to psi atm X 14.696
2
atmosphere (standard) to Kg/cm atm X 1.0332
2
atmosphere (standard) to Kg/m atm X 10332
atmosphere (standard) to kPa atm X 101.325

3. Length

inches to meters (m) in. X 0.0254

inches to centimeters (cm) in. X 2.54
inches to millimeters (mm) in. X 25.4
meters to inches (in.) m X 39.37
centimeters to inches (in.) cm X 0.3937
millimeters to inches (in.) mm X 0.03937
mills (0.001") to millimeters 0.001" X 0.0254

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 13

4. Flow
3
cubic feet per minute (scfm) to cubic meters per second (nm /s) scfm X 0.0004719
3
cubic feet per minute (scfm) to cubic meters per hour (nm /h) scfm X 1.699
cubic feet per minute (scfm) to cubic centimeters per second scfm X 471.9
3
(cm /s)
3
cubic feet per minute (scfm) to cubic meters per minute (nm /m) scfm X 0.02832
3
1000 scfm = 28.32 nm /m
3 3
cubic meters per hour (nm /h) to cubic meters per minute (scfm) nm /h X 0.016667
3 3 3
cubic meters per hour (nm /h) to cubic meters per second (nm /s) nm /h X
0.00027778
3 3
cubic meters per minute (nm /m) to cubic feet per minute (scfm) nm /m X 35.315
3
gallons per minute (US) to cubic meters per minute (nm /m) gpm X 0.0037854
3
gallons per minute (US) to cubic meters per hour (nm /h) gpm X 0.2271
gallons per minute (US) to cubic feet per hour (scfh) gpm X 8.021
gallons per minute (US) to liters per second (L/s) gpm X 0.06309

5. Volume
3
gallons (US) to cubic inches (in ) gal. X 231
3
gallons (US) to cubic meters (m ) gal. X 0.0037854
gallons (US) to liters (L) gal. X 3.7854
3
liters (L) to cubic inches (in ) L X 61.024
3
liters (L) to cubic meters (m ) L X 0.001
liters (L) to gallons (US) L X 0.26418
3 3 3 -
cubic inches (in ) to cubic meters (m ) in X (16.387 X 10
6
)
3 3 3
cubic meters (m ) to cubic inches (in ) m X 61024
3 3 3
cubic meters (m ) to cubic ft. (ft ) m X 35.315
3 3 3
cubic feet (ft ) to cubic meters (m ) ft X 0.02832

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
14 CENTAC TROUBLESHOOTING GUIDE

6. Electrical
Amps (I) = current
Ohm (R) = resistance
Watts (W) = electric power
kw
Kilowatts (KW) = electric power
Power Factor (pf) =kva
Kilovolt - amps (kVA) = apparent electric power
Kilowatt hour (KW/hr) = unit of electric energy or work performed
Joule (J) = metric unit of energy in watt per sec.
Volt (E) = unit of electric pressure or electromotive force
eff = efficiency (expressed as a decimal)
pf = power factor (expressed as a decimal)
hp = horsepower output
AC = alternating current
Ohms Law Relationship (direct current - DC)

W E2
E= W=
I R
E = WR W = I 2R
E = IR W = EI

E W W E W E2
I= I= I= R= R= R=
R E R I I2 W

IE 1. 73IE
kva = ( single phase AC) kva = (3- phase AC)
1000 1000
IE IE ( pf )
KW = (DC) KW = ( single phase AC)
1000 1000

1. 73 IE ( pf )
KW = (3- phase AC)
1000

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 15

6. Electrical, continued
IE ( eff ) IE ( eff )( pf )
hp = (DC) hp = (single phase AC)
746 746

1. 73IE ( eff )( pf )
hp = (3- phase AC)
746

IE IE ( eff )( pf )
J= (DC) J= (single phase AC)
sec sec

1. 73IE ( eff )( pf )
J= (3- phase AC)
sec

746( hp )
Amps(hp known) = (DC)
E ( eff )

746( hp )
Amps (hp known) = (single phase AC)
E ( eff )( pf )

746( hp )
Amps(hp known) = (3- phase AC)
1. 73 E ( eff )( pf )

1000 KW
Amps(KW known) = (DC)
E

1000 KW
Amps(KW known) = (single phase AC)
E ( pf )

1000 KW
Amps(KW known) = (3- phase AC)
1. 73 E ( pf )

1000kva
Amps(kva known) = (single phase AC)
E

1000kva
Amps(kva known) = (3- phase AC)
1. 73E

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
16 CENTAC TROUBLESHOOTING GUIDE

7. Vibration
2
A = Acceleration in g's (in/sec ) = Peak
V = Velocity in in/sec = Peak
D = Displacement in mils = Peak - Peak
f = Frequency in Hz

A
V = 61. 34
f V = 0. 0031416 f D

V A
D = 318. 3 D = 19 , 570
f f2

A = 0. 0000511 D f 2 A = 0. 0162 V f

RMS (root mean square) = 0.707 X RMS = 1.111 X average RMS = 0.354 X Pk - Pk
Peak
2
average = 0.637 X Peak average = 0.900 X RMS average = 0.318 X Pk - Pk

Pk - Pk (Peak to Peak) = 2 X Peak Pk - Pk = 2.828 X RMS Pk - Pk = 3.142 X average

Pk (Peak) = 1.414 X RMS Pk = 1.571 X average

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 17

0.707
0.637
+
0
AVERAGE RMS PEAK
-

PEAK TO PEAK

in / sec. = mm / sec. 0. 03937

mm / sec. = in / sec. 25. 40

12000
total vibration(in mils) = 1. 25
RPM

8. Water Quality Requirements

Total hardness (expressed as CaCo3) less than 100 PPM

Suspended solids less than 50 PPM
Maximum water temperature (cooler discharge) 140F/60C
pH range 6.0 - 8.5
Langlier saturation index (LI) +0.5 - +1.0

A low pH level promotes corrosion and high levels of dissolved oxygen.

A high pH level increases the chance of scale formation.
A low LI indicates the water tends to be corrosive.
A high LI indicates a tendency to form scale.
It is recommended to contact a reputable water treatment professional if there are questions
regarding water quality.
Rev. C
24 Mar. 1995

CST-TP0007
1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94