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Troubleshooting PDF
Troubleshooting PDF
Troubleshooting Guide
INGERSOLL-RANDÒ
AIR COMPRESSORS
CENTAC TROUBLESHOOTING GUIDE
Copyright Notice
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
Ó 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
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
CENTAC TROUBLESHOOTING GUIDE 1
Surge
Cause Solution
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.
13. Restricted air flow through air coolers. Clean air coolers.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
2 CENTAC TROUBLESHOOTING GUIDE
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 3
6. System demand greater than Check for excessive air usage like open
compressor capacity. valves, leaking fittings, etc., and correct.
Start additional compressor. Recommend
that customer purchase another Centac if
additional capacity is required.
10. System air pressure sensing point in Relocate control air connection
wrong location.
12. Too low CLH setting. Increase setting (Do not exceed
FLA+SF).
14. Bypass valve stays open; inlet valve Lower CLL to activate bypass valve on
functions normally. MP3 panel. Ensure 2TR is operating
properly on Electro-Pneumatic panel.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
4 CENTAC TROUBLESHOOTING GUIDE
High Vibration
Cause Solution
3. Oil not draining properly from Investigate and correct. Check for
bearings. restriction, improper venting, too high oil
level.
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
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 5
1. Too small control air line. Replace with larger diameter pipe.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
6 CENTAC TROUBLESHOOTING GUIDE
Failure to Start
Cause Solution
12. Control circuit not grounded properly. Ground neutral at transformer. Check
wiring.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 7
No Control Power
Cause Solution
Failure to Load
Cause Solution
7. No power air to inlet or bypass valve. Investigate. Open power air shutoff valve.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
8 CENTAC TROUBLESHOOTING GUIDE
1. Incorrect relief valve adjustment. Adjust main oil relief valve to obtain 25-27
psi at correct operating oil temperature.
5. Leaking bullgear cover seal. Remove cover and install new silicone
sealant around oil supply groove.
11. Too big prime line. Install smaller prime line or remove
entirely.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 9
5. Dirty oil cooler on water side. Clean water side of oil cooler.
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.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
10 CENTAC TROUBLESHOOTING GUIDE
5. Water flow bypassing 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.
6. Water/glycol mixture greater than Adjust mixture to ensure the glycol is not
50/50. greater than 50%.
9. Air cooler oriented incorrectly. Remove air cooler and rotate to align the
water ports correctly with the water
connections of the casing.
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-Dec-94
CENTAC TROUBLESHOOTING GUIDE 11
2. Pressure – gauge
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94
12 CENTAC TROUBLESHOOTING GUIDE
3. Length
CST-TP0007
Ó 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
Ó 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 = I´R W = E´I
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
Ó 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
Ó 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
CST-TP0007
Ó 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
12000
total vibration(in mils) = 1. 25 ´
RPM
CST-TP0007
Ó 1994 Ingersoll-Rand Company
Date of issue: January, 1999 Supersedes: 16-dec-94