‘This manuals purpose isto enable the user to understand the construct ‘and function of various componentry associated with a Joy turbo alt centrifugal compressor. It sets forth proper insallatios, operation and iaintenance procedures which, if followed, will ensure long and satisfac- tory service. Since this is a general manual, these instructions may not cover all details ‘or variations in the equipment supplied, or every possible question in ‘regard to installation, operation and maintenance, Should situations arise that are not covered by these instructions, further information may be obtained through Cooper Sales and Service Representatives. WARNING This manual contains vital information for the safe use and efficient operation of this compressor. Carefully read the Operator's Manual before starting the unit. Failure to ad- ‘hereto the Instructions could result in serlous bodily injury. Warranty ‘Te Seles warrants tht ths compresorconfoms to splcable cravings and seston tions approved in wring bythe Seller and wil be fee fom defects in material end work ‘rani for prod of 12 mene fom the date oF inal operation or 15 month fom the dot of shipment, whichever pei fist expis.1f within tat period Seller receives {rom the Buyer witen atce of ay alleged det i or ne-conormce of, the com: pressor and if in Seller’ judgement the compressor does aot conform ors found to be de Festive In mati oc workmenship, Seer will, a option, either (a) fais a Service Repesemative 10 comet defective workmanship, ot (8) upon return of the component FOB Sellers plan a1 Buffalo, New York, repat or replace the component, ()retum the al purchase pice forthe compresoe witht into ‘Cooper's sole responshilty and Buyers exclusive remedy hereunder smite to sch r= pric replacemen oF repayment ofthe purchase pice. Equipment and acesoris furnished by third parties which ar nt incorporated in a com- ‘restr package manfared by the Seller ae waraate ony 0 the extent othe oil Imenfacuer’ warty tthe Selle. ‘THERE ARE NO OTHER WARRANTIES, EXPRESS, STATUTORY OR IMPLIED, IN: ‘CLUDING THOSE OF MERCHANTABILITY AND OF FITNESS FOR PURPOSE: KOR ANY AFFIRMATION OR FACT OR REPRESENTATION WHICH EXTENDS BEYOND ‘THE DESCRIPTION OF THE FACE HEREOR. ‘This wanaty shall be void and Slr shall have oo responsibilty to rep replace, ot repay the purchase price of detective or damaged compress o component parts result ing ety cindy from he ue of repute eplacement pas bot of the Seller's man- tecture oF approved by the Sele or from Buyer failure to store, inal, melt, ad ‘peas the compressor sccording tothe Selle’s writen iastucions, drawings and 0d fnginering practice. Deteniraton aad weer casioned by chemical and absve action sretceste het shall not const detect LIMITATION ON LIABILITY. See's total responsibilty for ary clims, damages, losses or liabilities arising out of or related to, is performance of the products covered hereunder shall ao exceed the purchase price. In no event shal Seller be lable for any special, indict, incidental or consequen {al damages of ay character, including, but nt limited Co, loss of use of prodetive ies or equipment, lot profits, prope damage, expenses incuted in reliance on Sel. Jer's performance hereunder o lost prodtion, whether suffered by Buyer or any hid pty. Seller discal Haitity for any and all cos, claim, demands, charges, ex eases, or other damages, either director tdiet, incident to all propery durageaisng fut of zy cause of action Based onset Hilt UNAUTHORIZED REPAIRS In the event that the customer has the compretsor serviced or reputed by unauthorized per sonrel, the coverage ofthe warranty policy Is automa Table of Contents Section 1 Recelving & Storage———] Section 2 Precautions Section 3 Description Section 4 Installation | Section 5 Piping Section 6 Shaft Alignment i Section 7 Lubrication Section 8 Electrical Connections Section 9 Control System Section 10 Operation : Section 11 Maintenance Section 12 Troubleshooting Section 13 Service & Parts | Section 14 Drawin, | Section 15 Motor & Starter Section 16 Supplemental Equipment| Contents Page TE HONING occ ec cence eee eens 1 MBit Storaget ec ce eres 12 Mlustrations Figure 1-1. Lifting Diagram See Seen Figure 1-2. Lift Points ae sea 2 Ae | Advisory Notes | ecrieory ores NOTICE: Report ShippingDamage ... 2. peel | CAUTION: Insufficient Framework. i | WARNING: Hoist and Chain Rating for iting... 2... eee | NOTICE: Proper Storage... . wae eeaceaaa 1 Receiving & Storage ‘The TA-38 package is shipped as onc assembly. It includes the compressor, motor, control panel’ inlet = 77! Handling — guide vanes, lubrication system, and optional noise ‘The TA-38 has been designed to be lifted from four enclosure. Optional loose equipment purchased with _points. A spreader bar may be required to clear certain. the TA-38 are shipped as separate ifems. Individual motors. Acces to lift points inside enclosed units are items are listed on shipping documents. ‘gained through doors provided, or by removing corner Shipmentsare FOB, Bufalo,NY,USA, andbecomethe Panels property of the purchaser atthe risk of the purchaser. MAXIMUM PACKAGE WEIGHT 20,000 Ibs. Asrough handling enroute can damage the unit, careful 4 qyerhead hoists are unavailable, thc compressor may inspection should be made before accepting delivery ‘be moved on rollers, dollies or casters. These devices from the carrier. Any shortage, breakage or damage must be of sufficient strength and must be placed ONLY noticed atthe time of delivery should be indicated on nder the base between the lit points. the carrier's freight bill and signed by the driver or a representative ofthe carzer. NOTE Report any damage noticed after delivery to the carrfer at once. Request inspection by CAUTION All other structural framework Is of Insutti- lent strength to support the unit. the carrier and completion of a Concealed Damage Report. Spreader Bar / Spreader Bar Figure 1-1. Lifting Diagram. ad orm: 038010690,To prevent damage refer to Figure 1-2 and: 1, Do not use forklifts unless the entire unit is placed ‘on a substantial pallet which supports the base botween the lft points. 2. Donotmove the compressor by pushing against the enclosure or its framework. Push or pull only at the lift points, WARNING. Personnel safety and protection of the TA- ‘38 are the paramount consideration during Installation. As a minimum, use only a 15- ton holst and chain rated for the weight Involved and In good condition. 1.2 Storage ‘Your unit has been carefully prepared for a maximum three month indoor storage period before installation, Lubricant-compatible rust inhibitors protect all perat- ing surfaces. Storage must be within a heated, indoor area with minimum temperature cycling to prevent damage from condensate forming within the gearbox. For storage longer than three months, or in an uncon- trolled environment, contact your Cooper repre- sentative. MOTE Fallure to provide proper indoor storage or storage exceeding the three-month dura- tion can void your warranty. 5 Noles Erelosure Outtine ‘This trame wil not Support Weight ofthe compressor Inornal Lit Points External Lit ol Figure 1-2. Lift Points. 12Advisory Notes & Warnings: Page Electrical 21,22 Air Pressure 24,24 Temperature. 22 OllPressue 2. ee 22 Filtration eee ereeeeeeeee 2:2, 28 Rotating Parts Seay Seay 2. 28 Cleanliness 2.2... es bees 23©21 Air Compressor Operating and Safety Precautions ‘An air compressor is a high-speed rotating piece of In addition to the many obvious safety rules, we suggest machinery. ‘The same common sense precautions _the following safety precautions associated with this should be observed as with any picce of machinery of type of equipment. this type. Carelessness in operation or in maintenance could result in serious injury to personnel. A WARNING HAZARDOUS VOLTAGE. CAN CAUSE SEVERE INJURY OR DEATH. © Disconnect all power gupplles, lock-out and display warning signs before servicing equipment. A DANGER AIR UNDER PRESSURE, WILL CAUSE SEVERE INJURY OR DEATH, © DO NOT operate the compressor at pressures In ex- ‘cess of the nameplate rating. Close the discharge block valve and relleve system of pressure before removing any caps or plugs, or servicing compressor. DO NOT play with compressed air, Wear eye protection when using compressed alr. AcauTion ELECTRICAL HAZARD. CAN SHOCK, BURN OR CAUSE DEATH. © All oloctrical enclosures and components must be installed and grounded In accordance with the Na- tlonal Electric Code and other local codes. 2 Form: 00802-0190Awanninal HIGH SURFACE TEMPERATURES. CAN CAUSE INJURY. © Some surfaces of the compressor and motor have excessive temperatures. To avold burns, keep hands and other body parts away while unit is operat- ing. APANGER HOT OIL UNDER PRESSURE. WILL CAUSE SEVERE IN- JURY OR DEATH. ‘© Shut down compressor and pumps before removing any caps or plugs, or servicing any parts. Avancer DO NOT USE DISCHARGE AIR FOR BREATHING OR FOOD PROCESSING, ASIT WILL CAUSE SEVERE INJURY ‘ORDEATH. © Air from the compressor used for these processes must meet OSHA 29 CFR 1910 or FDS 21 CFR 178.3870 filtration regulations. Accaution ELECTRICAL OR CONTROL HAZARD. COULD CAUSE INJURY OR MACHINERY DAMAGE. ‘© DONOT rewire or place jumpers in the contro! pane! without written consent from the Cooper Engineer- Ing or Service Departments. ® Periodically check all safety devices for proper ‘operation. 22» & & Awaaninal ROTATING SHAFTS COULD CAUSE SEVERE INJURY OR DEATH. © DO NOT remove protective guards while the com- pressor Is In operation. © DO NOT attempt to service any part while the ‘machine Is operating. Awarninai 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. A caution! ‘© Exercise cleantiness during maintenance and when ‘making repairs, Keop dirt away by covering parts and ‘@xposed openings witha clean cloth. © Be sure no tools, regs, or loose parts are left on tho compressor or drive parts. © DONOT use flammable solvents for cleaning parts AwaRMing, © DONOT operate the compressor inareas where there Isa possibility of ingesting flammable or toxic fumes. 23AcauTion © Pressure vessels (recelvers, aftercoolers, dryers, ete.) may require ASME Code (CRN in Canada) stamp- {ng to meet local codes. © Investigate cade requirements before operation to ‘make sure all requirements have been met. The owner, lessor or operator of the compressor Is hereby notified and forewarned that any failure to observe common safety precautions, whether stated herein or not, may result In damage or injury. Cooper Industries expressly disclaims responsibility or ability for any Injury or damage caused by fallure to observe those specified, or other common precautions or by fallure to exercise that ordinary caution, common sense and due care required In operating or handling the compressor even though not expressly specified abov 24SS Seetion 3 Summary ts Page 34 Features 6 eee eee eee at ittree Air ‘Simple Installation Low Maintenance Costs Power Savings Effective Sound Attenuation aso of Operation Warranty ‘Standard Equipment Optional Accessories 3.2 Subsystem .. . Compressor and Driver Intercoolers Lubricating System Control System Ilustrations ) Figure 3-1. Major Components ey ae 32 Advisory Notes NOTICE: PatentProtection ......... Beat 84‘The Joy® Turbo Air 38 compressors an advanced state- ‘of-the-art contrfugal compressor providing oil-free plant air for application inthe 700 to 800 hp range. A proven, full pre-engineered design reduces initial investment. Durable construction, ease of installation and maintenance, and its energy conserving microproccs- sor control, make the TA-38 economical to install and operate. The microprocessor tailors compressor out- put to plant demand. ‘Several TA-28 components are protected by U.S. and Japanese patents. 3.1 Features © Oilsree Air. Individual air and oil seals are separated by atmospheric space. This design con- fines the compressed air flow path, preventing, contamination by lube oil. Delivered air is in- herently oibfree. ‘© Simple Installation. Designed for ease of installa- tion, The compressor, intercoolers, lube system, control panel and driver motor are packaged in one unitized design. When the optional noise enclosure is ordered, a separate structural basc is provided to support the compressor package and the enclosure. The standard controt mode (Auto-Dual) does not require instrument air for start-up or operation. Foundation and holddown requirements are mini- mal. ¢ Low Maintenance Costs. Built to last with top quality components. Stainlesssteel impellers resist corrosion and erosion. Impellers are driven at their optimum speeds through an integral gear arrange- ment elimiating high-speed couplings. Intercooler tubes are mechanically cleanable and can be serviced without dismantling air piping or ‘other compressor components, Cast iron inter- cooler housings require no servicing. Gears, bearings and seals are casly accessible because of Turbo Air's horizontally split case and separate intercooler compartment. Periodic replacement of ‘compressor mechanical parts are not required. ‘© Power Savings. The QUAD Il microprocessor con- trol system drives the variable inlet guide vanes to respond automatically to variations in ambient condi tions and in load requirements. Less power is used during reduced demand periods. ‘These features translate into savings of up to 9% of the annual compressor power consumption. ‘The QUAD Ill system maintains constant pressure output, or motor current limited operation, protects against compres- sor surge and unloads the compressor during periods of reduced demand. No-load power consumption is ‘exceptionally low. Effective Sound Attenuation. Designed to perform below maximum OSHA sound levels in effect as of June 1981. ‘© Ease of Operation, Completely unattended opera- tion, The allelectronie control pane! features a ‘microprocessor to provide reliable machine protec- tion as wel as flexibility of output over a wide range of operating conditions. © Warranty, Twelve month buyor warranty assures quality of workmanship and guarantees against ‘material defects. Fullwarranty appearson the front age. © Optional Accessories. The compressor package ‘containing intercoolers, lubrication system, control panel and driver is complete and shipped ready to install into the uscr’s air system, Some control devices like the bypass/blowoff valve and peripheral ‘equipment may be required to make an air system complete. The following items are available: inlet filter/silencer, start-up sereen, flexible air pipe cou- plings, aftercooler with moisture separator, air ‘dryer, mounted bypass valve (some applications), blowoff silencer, block valve, receiver, water manifold, water control valves, closed-loop water cooling system, special heat exchanger mat condensate removal system, dual oil filters, oil heater, oversize oil cooler, buffered oil seals and a noise enclosure. 3.2 Subsystem Description Location of the major components and subsystems is identified in Figure 3-1. ‘© Compressor and Driver. The driver is flexibly coupled tothe compressor integral gear drive. T ‘ear set increases the rotation to the optimum im- peller speed for best flow and efficiency. ‘age-matched sigma radial impellers provide effi cient compressioa in two or three stages. Separate, horizoataly spit Labyrinth air and oil seals prevent ‘ontannination ofthe air stream by lubricating ol. orm: 03803-0690,Figure 3-1, Major Components. 32Intercoolers. An extended surface, plate-fin design provides maximum heat transfer with minimal space requirements. The air-in-shell, water-in- tube concept flows water through unrestricted tubes for easy accessibility for inspection and rod or chemical cleaning, No disassembly of other com- pressor components or air piping is required. Standard materials include copper tubes, aluminum fins and steel tubesheets, A variety of alternative materials are available for harsh en- vironments. Where contaminated air is a problem, copper fins and phenolic coatings are available. Entrained moisture is separated by extended fins combined with two 90° changes in air direction at low velocities. Lubricating System. Cooled, filtered ois supplied by the lubricating system, An electrically driven, low-pressure pump draws oil from the reservoir and supplies itto the system through an oil cooler and filter. A shaft-driven high-pressure pump lubri- cates the bearings and gear mesh, This "back-up" ube pump system provides pre-lubrication as well as safe shutdown in case of power loss or pump failure. Control System. The Quad Ill System is a true breakthrough in compressor control design. Al- though extremely simple to operate, it provides sophisticated controls found in NO OTHER com- pressor control system. Major features include: Three types of output control: — AUTO-DUAL (Pressure) — CONSTANT PRESSURE (Pressure) — CONSTANT MASS FLOW (Mass Flow) ‘Motor current limiting control. 33 Surge control. Automaticno-load operation during periods of ow demand (AUTO-DUAL Control). Minimal blow-off during periods of low demand (CONSTANT PRESSURE/CONSTANT MASS FLOW Control), Adaptive control logiclearns and self-adjusts tosuit widely varying customer air system characteristics, and compressor operating conditions. Automatic shutdown with first-out display in the event of a serious problem. User-friendly panel incorporates a two-line, 80 character alphanumeric display capable of provid- ing over 200 messages of compressor conditions, Recall capability of principal compressor operating, ‘measurements including a time and date stamp, Vibration of the low-speed rotor is monitored by a xnon-contacting, proximity probe located outboard of the bearings near the impeller, ‘The first stage is. most susceptible to the affects of dirt buildup and other foreign material entering the compressor. Dual level protection (ALARM and TRIP) of a normal operation is provided. Additional channels, lable to monitor subsequent stages if Self-diagnosis of all measurement transducers and power supply voltages. Self-diagnostic software to help the operator locate problems quicklyby answering aseries of questions. Many control options.