1CV_MX2 &

2CV_MX3
Centrifugal
Compressor System
 Topics

• Basic operation of CENTAC

• Major parts description
• Air Flow System and water system
• Instrument System
• Lubrication System
• CMC control and auxiliaries
• Maintenance
Basic Operation
of CENTAC
 Introduction

The CENTAC compressor is a dynamic

centrifugal air compressor driven by an
electric motor. The compressor and driver
are direct coupled and the entire unit is
mounted on a common baseplate with its
own lubrication system, control system
and auxiliaries.
 Introduction
The compressor package contains :
• A main driver that directly drives the bullgear that is
common to all stages
• Compression stages consist of an impeller mounted
on its own shaft and diffuser facing the impeller,
enclosed within a common cast iron casing
• Rotors consisting of an integral pinion gear driven at
its optimum speed by a common bullgear
 Introduction

• An intercooler is mounted at discharge of every stage

• A drainage hole provide at lowest part of air cooler to
remove condensate
• In some compressor configurations, an aftercooler is
also mounted on the package
 How CENTAC compress Air
• By imparting kinetic energy to the air, 2/3 of that
stage design pressure is achieve in impeller.
The remaining 1/3 of the stage design pressure
is achieve at the stationary diffuser
• This sequence repeats in each succeeding
stage until the compressor achieves the desired
operating pressure.
 Impeller
2/3 of Design
Pressure
achieved in
impeller
 Diffuser
• Converts
Velocity energy
to Pressure
energy
• 1/3 of
compression
achieved
passing through
stationary
diffuser
 Ideal Head Plot
Ideally there should be a
one to one ratio between
the pressure developed
by the compressor and
PSIA the discharge capacity
Therefore the Ideal Head
Plot would give a linear
pressure output for a
given flow condition.
Inlet (ICFM)
 Losses in Compression
However this is IDEAL
and does not account for
the losses that occur in
real life!
PSIA Losses such as
Friction
Restriction
Heat

Inlet (ICFM)
 Actual Head Plot
Accounts for Energy
LOSSES in a real
compressor.

PSIA

Inlet (ICFM)
 Useful operating range

The actual
operating range is
limited.
Surge Choke
Too low of a flow
in a compressor
PSIA

Useful operating will result in

range SURGE
Too high of a flow
results in a
Inlet (ICFM)
CHOKE condition
 Surge

Surge is the reversal

of flow through a
J P centrifugal
compressor due to a
reduction in flow
K Q through the
PSIA
compressor.
- flow 0 + flow Typically noted by
the ‘WHOMP’ sound
in the compressor.
 Surge
Natural Surge Point
5% minimum from Surge line
Actual Head plot
Throttle Limit (TL)
Pressure

IV Throttle Range IV = 100%

Or IV control sys. pressure

IV = TL
BV modulating

Throttle Surge Point

Choke

Flow
 Surge Terminology in CENTAC

• Throttle Surge – When flow across the compressor

drops till the surge line while maintaining constant
pressure.
• To prevent such occurrence, the bypass valve is open
before reaching the surge point
• Natural Surge – When pressure reach the maximum
the compressor can compress (exceed the physical
limitation of the compressor).
• Typically 110% of compressor rated pressure
 When will Surge occurs?

• Damage or foreign object build up in the diffuser and

impeller
• When system demand decrease too fast than the inlet
valve can react to the change
• Temperature changes
• Foul up air cooler
• Etc……
 Choke

• Compressor physically cannot pass any more air

volume due to losses being encountered either
in the compressor itself or in the discharge
system
• Choke is a fixed physical limit of the compressor
• If system calls for more air than the compressor
can supply, pressure will drop till the choke
condition exist
Major
Components
 Rotor Assembly
Rotor Assembly imparts velocity to air
entering the compression
Rotor assembly consists of an efficient
and high quality stainless steel impeller
and a removable thrust collar mounted
on an helical geared pinion shaft.
The impeller is secured to the shaft by a
polygon slot attachment and the thrust collar is
secured to the shaft with a polygon
attachment.
All rotating parts are dynamically balanced
as a complete assembly
 Diffuser

Stationary diffuser converts velocity

of the air to pressure
The diffuser is located between
each impeller and cooler
The diffuser are designed for
maximum efficiency while limiting
physical size, thereby keep the
compressor as compact as possible
 Diffuser

Diffuser Vanes

Diffuser Contour Surface

maintains impeller air gap
Thrust Bearing
Bearings

Thrust loads are absorbed at each

pinion by a hydrodynamic thrust bearing.
The thrust bearings are designed to
maximize load carrying capacities and to
Plain Bearing minimize power loss.
The journal bearings are babbit lines,
fixed tilted pad design for maximum
stability and load capacity with minimum
power loss.
Bullgear bearings incorporate a
hydrodynamic design.
Journal & Journal Bearings
Fixed tilted pad bearing

Fixed Tilted Pad Bearing

 Seal cartridge

A single cartridge seal is mounted in

the plain bearing housing behind each
impeller.
Each cartridge consists of four, one
piece, fully floating non-contact carbon
rings.
One ring is used as an air seal and
the remaining two as oil seals. Buffer
air supplies air to the oil seals assuring
that lube oil is not drawn past the seals,
thus ensuring oil free air.
Air & Oil Seals
• Non-contacting carbon ring type
- full floating
• Unsurpassed seal life
• Single piece construction (not
complicated or split)
• Less than 1% air leakage as
compared to other designs which
leak 3 - 5%
• Guaranteed 100% oil free air
under all operation conditions
Air & Oil Carbon Seal
Seal Air 10-15 p.s.i.g
Air Vented to
atmosphere
CENTAC Air
Air Seal
Seal
Seal Air Injection
(12-15 Psig)
S V Oil Pressure
e (Approx. 25 Psig)
at n
g t
e
P T
Diffuser r o
e A
s t
s m
u
r o Oil
e Air s Oil
Seal . Seal Seal

Inlet Im peller Pinion Plain

Bearing
Air

INGERSOLL-RAND
 Condensate System
•Removes condensate from the
compressed air
•Inlet air contains water vapour which
condenses to form liquid water when air
is cooled after compression
•Minimized condensate carrying over
into the next stage
PNLD PNEUMATIC NO LOSS DRAIN
NO LOSS DRAIN TRAPS USED IN FIELD
Damage Parts when auto drain traps failed and completely choke:
Note: This pictures was taken in SOVIGAZ Vietnam when operators did not service
the auto drain traps for one year of running and warranty don’t cover parts failed
due to poor maintenance by customer
 Air Filter Assembly
Filter dust, dirt, carbon and
any foreign object before
clean atmospheric air is
compressed

Consist of three 4 micron

pre-filter and three 2 micron
filter
Located in compressor room
 Silencer

Absorb noise when air is

bleeding off to atmosphere
Located in compressor room
Vent hole located at wall
Air Flow system
Diagram
 Air System
Air Filter IC MS IC MS IC MS

IGV
1st Stg 2nd Stg 3rd Stg

CV

To System
BV

Silencer CENTAC
To atmosphere
CENTAC
Instrument Air
system
 INSTRUMENT AIR SYSTEM
IA to IV & BV with
Isolation Valve pressure range 65
– 120 Psig
Instrument Air
Supply

Seal Air with

Pre-Filter
pressure range 10
– 15 Psig

Pressure
Regulator
 Instrument Air System

• Before the compressor can be started, instrument air

is required for proper inlet and bypass valve operation
and also to provide seal air for the air/oil seal
assembly of all the compression stages
• Seal air pressure is 10-15psi (0.67Bar-1.03Bar)
• Valves operating pressure is 65-120psi (4.57Bar-
8.3Bar)
AD IA
comp
Comp#8 Comp#1

Comp#2

Comp#3

Comp#4

Comp#5

Comp#6
CUSTOMER
Comp#7
INSTRUMENT AIR SYSTEM
 IA START UP COMPRESSOR SYSTEM WITHOUT
AD
comp INSTRUMENT AIR
Comp#8 Comp#1

Comp#2 Main header valve

Comp#3

IA pressure
Comp#4 regulator &
STEP 1; Close IV/BV
instrument air isolation
valve IV/BV and valve
pressure Comp#5
regulator of seal
air on comp 1 to
7 while keeping
the comp 8
Comp#6
instrument air CUSTOMER
valves open.
Also close the Comp#7
INSTRUMENT AIR SYSTEM
valve at main
header
 IA START UP COMPRESSOR SYSTEM WITHOUT
AD
comp INSTRUMENT AIR
Comp#8 Comp#1

Comp#2 Main header valve

Comp#3

IA pressure
Comp#4 regulator &
STEP 2; Test IV/BV
run the IA isolation
compressor and valve
Refrigerated air Comp#5
dryer and
monitor the IA
pressure must
have minimum
Comp#6
of 65 Psig to CUSTOMER
IV/BV pressure
gauge of Comp Comp#7
INSTRUMENT AIR SYSTEM
8
 IA START UP COMPRESSOR SYSTEM WITHOUT
AD
comp INSTRUMENT AIR
Comp#8 Comp#1

Comp#2 Main header valve

Comp#3

IA pressure
Comp#4 regulator &
STEP 3; Test run IV/BV
the Comp 8 and isolation
load test then valve
monitor the system Comp#5
pressure in CMC
display until
pressure reached
Comp#6
to minimum of 65
Psig CUSTOMER
Comp#7
INSTRUMENT AIR SYSTEM
 IA START UP COMPRESSOR SYSTEM WITHOUT
AD
comp INSTRUMENT AIR
Comp#8 Comp#1
Instrument air
Comp#2 supply of Main
header valve

Comp#3

IA pressure
Comp#4 regulator &
STEP 4; Open IV/BV
the IA valve of isolation
main header valve
Comp#5

Comp#6
CUSTOMER
Comp#7
INSTRUMENT AIR SYSTEM
 IA START UP COMPRESSOR SYSTEM WITHOUT
AD
comp INSTRUMENT AIR
Comp#8 Comp#1

Comp#2 Main header valve

Comp#3

IA pressure
Comp#4 regulator &
STEP 5; Open IV/BV
the IA pressure isolation
regulator and valve
isolation valve Comp#5
of Comp 2 to 8
then test run &
load test one
compressor at
Comp#6
the time until all CUSTOMER
compressors
are running Comp#7
INSTRUMENT AIR SYSTEM
loaded
 IA START UP COMPRESSOR SYSTEM WITHOUT
AD
comp INSTRUMENT AIR
Comp#8 Comp#1

Comp#2 Main header valve

Comp#3

IA pressure
Comp#4 regulator &
STEP 6; Enable IV/BV
remote Switch on isolation
all compressors valve
and Reset the Comp#5
CEM to monitor
the compressor
system from CEM
Comp#6
CUSTOMER
Comp#7
INSTRUMENT AIR SYSTEM
Inlet Valve - Butterfly

The butterfly valve is most

common used in CENTAC
applications.
Consist of an I/P transducer to
converts 4-20mA signal to
pressure to actuate the
mechanical valve
Typical instrument air
requirement is 65-120 psig for
proper valve operation
Vacuum Gauge
Measures the pressure
differential of air after filtration
against atmospheric air to
determine the condition of the air
filters
Vacuum Gauge provide
warning if values exceed 8 inch
of H2O
 Blow-off Valve (Bypass/Bleed)
The blow-off valve is to bleed air
to the atmosphere when air
produced exceed the usage.
Types of bypass valve – Butterfly
Has a I/P transducer which
converts 4-20mA signal to pressure
to move the actuator
Typical instrument air requirement
is 65-120 psig (4.57Bar-8.3Bar) for
proper valve operation
 Instrumentation - Temperature
RTDs
– 0-500F (0-204.4C)
RTD Range
– 2 Wire With
Transmitter
• Stage 1, 2 and 3
Air
Temperatures
• Oil Temperature
• Cooling Water in
Temperature
 Instrumentation - Pressure
• Pressure Transducer for
pressure readouts
– Range 0-50psi (0-3.45Bar),
0-200psi (0-13.79Bar)
– Pressure transmitters Used:
• Oil pressure
• Stage 1, 2 and 3 air pressure
• System pressure
 Instrumentation - Vibration
• Vibration system consist
of a probe, a transmitter
and a cable
• Measure the radial and
axial vibration of a rotor
assembly
• Probe is installed at all
stages housing
• Transmitter convert
Voltage gap from the
probe to 4-20mA for
readout in OUI
 Vibration probes Vibration Probe & Cable

A non-contacting
vibration probe is
mounted in each plain
bearing
The vibration probe
Vibration Transmitters
measures the radial
vibration of each rotor
assembly
The probe is connected
to a vibration transmitter
for protection and
readout
Lubrication
System
Pre-Lube Pump Running in
Lubrication system
Oil Filter PRV

Oil Mixing
Valve

Oil Cooler X 2
1st/2nd

Stage Driver
Main Oil pump Demister
Assembly

Prelube
pump &
Oil level
motor
Gauge

PRV Heater x1
Oil Reservoir
 Lubrication system
Oil Filter PRV

Oil Mixing
Valve

Oil Cooler X 2
1st/2nd

Stage Driver
Main Oil pump Demister
Assembly

Prelube
pump &
Oil level
motor
Gauge

PRV Heater x1
Oil Reservoir
Demister Assembly
Demister are
design to trap
vaporize oil fumes
and mist and
condense it back to
liquid oil
 Oil Reservoir Heater
Oil reservoir heater are
provided to heat the oil in
the reservoir to preset
temperatures
If oil temperature is too
low, condensation occurs
and water formed in the oil
1 heater is installed in the
reservoir
Work in conjunction with
built in thermostat
 Oil Pressure Relieve valve
Pressure relief
valve to control oil
pressure going into
the bullgears
Typically adjusted
to 25 to 35 psig

Adjustment
From pump

To reservoir To bullgear
Thermostatic Expansion Valve

To provide proper
injection temperature
to the compressor
bullgear assemblies

105-115degF 95degF

140degF
Thermostatic Element
 Oil Filter Assembly
Oil filtration consist of a dual
oil filter assembly with manual
valve to select which filter to
use or standby.
Oil filter are used to trap
unwanted particles in the oil
system
10 micron filter element
Prelube Pump and Motor
Allow oil circulation
when control power
is “on” and machine
is not running

Is driven by an
electric motor
 Main Oil Pump
Circulate oil when the machine is
running
Driven by the bullgear
 Main Oil Pump

Circulate oil when the machine is

running
Driven by the bullgear shaft
through gear.
 Oil Cooler
To remove heat
from the oil
Water in tube, oil in
shell
2 pass oil cooler
Hot oil in Cool oil out
Water out

Water in
 CENTAC®
MicroController
 Topics

• Major components of CMC Panel

• Mode of Operation
• Compressor operating states
• How to use the OUI
• Start Sequence of CENTAC
• Stop Sequence of CENTAC
 Topic 1
Major Components
of the CMC panel
 Introduction

• The CMC panel is the microprocessor-based

control and monitoring system for CENTAC
compressors. The CMC handles all pressure
control and monitoring functions; as well as,
control auxiliary equipment such as the main
motor starter, oil heater, and prelube pump.
Features
Ease of use ... only twelve buttons to push on the
operator OUI!
Multiple function, 240 x 128 pixel graphic LCD
display to display data and operating status
Modulate and Auto-Dual operating modes.
Manual Mode feature used for testing the
CENTAC performance and calibration only
Advanced surge detection and control.
High current limit for main drive electric motor
protection.
Features
First-out indication and event log to help determine
the root cause of a compressor trip.
Pinion vibration alarm and trip for each compression
stage.
Optional port for communicating to the Centac
Energy Master (CEM) or other Distributed Control
Systems (DCS) via MODBUS protocol.
 Major Components of CMC
• Base Control Module (BCM)
– Performs all control and monitoring functions.
• Operator User Interface (OUI)
– Allows display and editing of operating points.
• Universal Communication Module (UCM)
– OPTIONAL on New Units.
– Allows for external communications to BCM.
• Instrumentation & Support Components
– Provides input for monitoring and controlling the
compressor.
 Base Control Module (BCM)

• Provides control
functions of the
compressor and also
monitors critical
instrumentations
• Located inside the
Control panel
 Base Control Module (BCM)
• Analog Inputs
• Analog Outputs
• Digital Inputs
• Digital Outputs
• OUI (RS232)
• Network (RS485)
• Current Input
• Fuses
• Battery
 BCM – Fuses & Battery
• Fuses (5X20MM, 1.5 Amp GMA Fast Blow)
• F100 - For BCM CPU card. (If blows call for service)
• F101 - For OUI
• F102 - For Analog Inputs/Outputs
• F103 - For Digital Inputs
• Battery (Tadiran TL-5101 3.6V 1/2AA Lithium)
– 10 Year Life expectancy
• Event Log
• Hours
• Starts
• Date - Time
• Non-Essential Parameters
BCM – Fuses & Battery
 Operator User Interface (OUI)
• An interface between
user and the controller.
Display to provide
readout of all information
from the BCM and
keypad to allow scrolling
through the different
menu available and
changing setpoint and
control the machine
• Located on front panel
door
• Black Bezel Cover for
NEMA 4 Rating
 Operator User Interface (OUI)
• 240 X 128
Graphical LCD
Screen
• Touch Pad
Overlay
– Acknowledge
– Reset
– Start
– Stop
– Load
– Unload
– Edit/Enter
– Navigational
– Contrast
 Universal Communication Module
(UCM)
• Used for external
communications with
system such as PLC,
SCADA or BAS, PC &
Software
• Support
communication protocol
such as RS422/RS485
Modbus, and Allen
Bradley DF1
• Located inside the
control panel
 Topic 2
Control Mode of
Operation
 Control Modes

• Types of Control Schemes

–Manual

–Modulate

–Auto-Dual
 Manual Mode
Manual Mode is operate by user
or operator manually by switching
to load then adjust the bypass
valve gradually to close until the
system pressure reach the set point
X
pressure
Inlet valve will start to throttle
from 100% until it reach the surge
line depending on operator’s
setting on bypass valve
Manual Mode basically using
for testing the CENTAC minimum
and maximum performance
 Modulate Control
Modulate Control
Characteristics
–Constant Pressure
Discharge

–Useful Inlet Valve

Throttling Range

–Unused (wasted)
Bypass Air

–Compressor Never
Unloads
 Auto-Dual Control
Auto-Dual Control
Characteristics
–Provides Useful Inlet Valve
Throttle Range
–Reduced Cycling of
Machine
–Allows Compressor to
Unload for Energy Savings
–Best of Both Worlds -
Modulation and
Load/Unload or two steps
–Adjustable Unload Point
and Timer
 Topic 3
Compressor
Operating States
 Compressor Operating States
• The different operating states dictates the control
of the inlet and bypass valves

• Waiting • Loaded
• Not Ready• Full load
• Ready • Max load
• Starting • Unloading
• Loading • Unloaded
• Minload • Coasting
 Waiting
• When power is re-
applied to
compressor
• To prevent machine
from restarting after
re-application of
power immediately
after power loss
• Allows proper oil
circulation before
the machine can be
re-started
Inlet Valve : 0% , Bypass Valve :
100% • Default is 120 secs
 Not ready
• When there is an
trip or stop
command has been
issued
• Press reset to clear
the trip if the
problem had been
rectified
• E-stop is pressed

Inlet Valve : 0% , Bypass Valve :

100%
 Ready
• This state is entered
when all
compressor
permissive
functions have been
satisfied

Inlet Valve : 0% , Bypass Valve :

100%
 Starting
• Will transit to this
state once a “start”
command is issued
locally or remotely
• Stage vibrations &
temperatures alarm
and trip setpoint are
increased (Trip
Multiplier Active)
during this period to
get the compressor
Inlet Valve : 12% , Bypass Valve : through the critical
100% speed region
 Starting
• Will always be in
Unload during
starting
• Prelube pump will
stop after this state
• Settings :
Depending on time
taken to run to rated
speed. Maximum is
60 secs

Inlet Valve : 12% , Bypass Valve :

100%
 Unloaded
• After the starting
period, compressor
will transit to last
selected load or
unload.
• Eg. If machine was
running loaded
previously before a
stop command, the
next time the
machine start, it will
load after the
Inlet Valve : 12% , Bypass Valve : starting period
100%
 Unloaded
• When machine is
running unload, the
inlet valve opening
can be set in the
“Settings” folder
• Typical setting will
depends on the 1st
stage pressure. A
positive pressure
must be maintain to
prevent vacuum,
instability of rotor
Inlet Valve : 12% , Bypass Valve : assembly and oil
100% carry-over the seal
 Loading
• Upon a load
command locally or
remotely, the
machine will transit
state to “loading”
• This state exist until
the Minload state is
satisfied and
duration depends
upon PID settings
for the inlet valve at
Inlet Valve : 45% , Bypass Valve : Minload state and
100% the demand for air
 Minload
• This state exist
when the bypass
valve is controlling
the pressure while
Inlet valve is
maintaining the
Minload Setpoint
• The bypass valve
will start to close if
system pressure is
below setpoint or
modulate if system
Inlet Valve : 45% , Bypass Valve : pressure exceed or
30% equal setpoint
 Loaded • This state exist
when the bypass
valve is closed and
the inlet valve is
controlling the
pressure
• IV will modulate
accordingly to the
system pressure
against setpoint
• Eg. If system
pressure is below
Inlet Valve : 75% , Bypass Valve : setpoint, IV will
0% continue to open
 Full Load
• This state exist
when the bypass
valve is closed and
the inlet valve is at
100% open
• The IV is not
maintaining the
system pressure
against setpoint

Inlet Valve : 100% , Bypass Valve :

0%
 MaxLoad • This state exist
when the Maxload
setpoint is reached
and the IV is
modulating to
control the motor
current to the
Maxload setting
• Maxload is to
prevent motor from
damaging after
running prolonged
period in excess of
Inlet Valve : 86% , Bypass Valve : its rated service
0% factored FLA
 Unloading • When unload is
issued locally or
remotely, the
compressor will
enter this state and
bypass valve will
ramp opens to
100% and inlet
valve will ramp
close till its Inlet
Valve Unload
Position
• Once both criteria is
Inlet Valve : 45 to 12% , Bypass achieve, will transit
Valve : 100% to “Unloaded” state
 Coasting
• When a trip or any
stop command is
issued and the
compressor is
running, the motor
will be de-energised
and the compressor
will begin to coast to
a standstill

Inlet Valve : 0% , Bypass Valve :

100%
 Coasting
• This state exist till
the timer set in the
“Settings” folder
expired and
prevents restarting
of compressor when
machine is still
coasting condition

Inlet Valve : 0% , Bypass Valve :

100%
 Topic 4
How to use the OUI
 How to use the OUI - Acknowledge

• Acknowledge button
–Silence the horn (if
available) or
acknowledge an
alarm
 How to use the OUI - Reset

• Reset button -
clears all trip
latches. Required to
be pressed after a
trip condition to
restart the
compressor.
• If fault exist, cannot
reset till it is rectified
 How to use the OUI - Start

• Start button – Starts

the compressor
 How to use the OUI - Stop

• Stop button – Stops

the compressor.
This button should
be pressed instead
of the E-stop for
normal operation
 How to use the OUI - Load
• Load button –
command to load
the compressor.
Engages Modulate
or Autodual control
mode depending on
the selection in the
“settings” folder
• Upon pressed, the
“load selected” will
be displayed at
bottom right
 How to use the OUI - Unload

• Unload button –
command to unload
the compressor.
• Upon pressed, the
“unload selected”
will be displayed at
bottom right
 How to use the OUI – Enter/Edit
• Enter/Edit Key –
toggles the display
between
Navigational mode
or the edit mode
• Pressing it will
highlight the
setpoint that can be
altered and
pressing again will
confirmed and
saved the new
values
 How to use the OUI -
• Navigational Keys –Navigational
arrow key for Up,
Right, Left and
down perform
differently
depending upon
current display
mode.
• During navigation
mode – keys used
to scroll through
different pages and
folders
 How to use the OUI -
• During edit mode – Navigational
up and down key
used to change
setpoint values. Up
for + and down for –
• During edit mode –
Left and Right key
is use to scroll
between different
parameters that can
be altered in that
page
 How to use the OUI - Contrast
• Contrast key –
changes the
contrast of the
backlight for graphic
LCD display
• Pressing this key
steps among the 16
contrast level and
when stepped to the
16th level, pressing
this key again will
returns to the 1st
level
Graphic Display
• 4 folders – System,
Info and Settings
• Status bar – shows
compressor
operating state and
status, control
location and folder’s
page number
• Page display
information such as
motor current,
pressure, date&
time and etc
Graphic Display – Status bar
• Compressor
operating states
• Control location :
– Remote
– Local
– Network
• Compressor status :
– Start Disable
– RMT – Stop
– Alarm/Trip
– E-stop
– Load selected
– Unload selected
Graphic Display – System folder
• 1st page always
display system
pressure, pressure
setpoint, motor
current, inlet &
bypass valve
position and date &
time
• This is the page
where the pressure
setpoint can be
changed
Graphic Display – System folder
• Analog input page
provides the actual
value for each stage
pressure, temperatures
& vibration and oil
pressure and
temperature
• Number of page
needed for such
display depends on the
total number of
information being
monitored
 Graphic Display – System folder
• Digital inputs page shows
the current state of the
digital input to the
controller and the inputs
will vary depending on the
optional inputs installed:
– Starter feedback
– E-Stop, Start Disable
– Low water flow, low seal air
– Starter Aux voltage
– Motor protection trip
– Remote comm/function
enabled
– Remote Start/Stop

• A check box indicates a true condition

Graphic Display – System folder
• Digital output page
shows the current state
of the digital outputs of
the controller :
– Prelube pump running
– CR1 (start relay)
– Remote trouble

• Check mark indicates a

true condition
Graphic Display – Info folder
• OUI Key map page
gives a brief description
of the buttons on the
OUI
• This page will be
displayed whenever
power is re-applied to
the control panel
Graphic Display – Info folder
• Event log page shows
events that occurs with
date and time stamped
such as alarms, trips,
commands initiated
and many others
• Event labeled as “1” is
the latest and “7” is the
oldest
• A total of 257 events
can be viewed
Graphic Display – Info folder
• To view other than
event 1 to 7, press
edit/enter button once
• The event numbers will
be highlighted.
• Then use the “up’ and
“down” navigational
button to scroll to the
next 7 events and so
on…..
Graphic Display – Info folder
• Last page of the info
folder page display the
power on hours,
running hours, loaded
hours and number of
starts
• It also display the BCM
software version in
used
Graphic Display – Settings folder
• 1st page in the settings
folder allows user to
enters password to
enable editing of
setpoints

• Also allows changing of

language (if supported)
and units of
measurement

• Date and time can also

be set in this page
 Graphic Display – Settings folder
•Units used in OUI
•To Change the unit of
measurement press
“ENTER” button
•Press UP/DOWN arrow
button in Navigational
Button to change units
•Press “ENTER” button to
confirm the changes in
units

NOTE: THE UNITS PROGRAMMED IN BCM IS IN ENGLISH WITH TEMPERATURE

IN Deg F, PRESSURE IN Psig, VIBRATION IN Mils AND SPEED IN RPM
Graphic Display – Settings folder

• Anti-surge settings
page allows the setting
of Maxload setting
(HLL), Minload setting
(TL), enable surge
3/11
indexing and setting of
surge increment and
also enabling of surge
absorber function
Graphic Display – Settings
folder • Surge happens 4 times
within 10 mins, the
compressor will unload
till reset by operator
• To enable the Surge
Absorber, check the
box
3/11
Graphic Display – Settings
folder • Surge Sensitivity
controls the sensitivity
levels of how surge is
detected.
• High value means high
sensitivity

3/11
Graphic Display – Settings
folder • Control parameters
page is used for
matching control
system to local
application
• PB, IT and D are
provided for both inlet
and bypass valves to
give controller precise
control over the valve
response to changes in
the air system
Graphic Display – Settings
folder • Control Mode Selection
page allows user to
select between two
standard control
modes, Modulate and
Autodual and also
manually controlling the
valves during
5/11 compressor setup
(commissioning or
troubleshooting)
Graphic Display – Settings folder
• Miscellaneous Settings
page allows user to set
the starting time, CT
ratio, inlet valve unload
position and setpoint
ramp rate

6/11
Graphic Display – Settings
folder • Alarm and Trip Settings
page provides a means
for changing the analog
health monitoring
values
• The number of
variables depends
upon the number of
compression stages
and optional input
Graphic Display – Settings folder

Main motor Power Calculation

Setting that displayed in page 1
of System Folder
Enable Backlight Auto Off will
automatically turn OFF the LCD
based on user set time

9/11
Graphic Display – Settings folder
Shows the Analog
Signal range and
actual values
Graphic Display – Service folder

Contact hot line

of Customer
Service
(65) 81813525 / 96720313 IR SEA
available 24/7
Graphic Display – Service folder
Consumable Parts List
Graphic Display – Service folder
Starting, stopping and maintenance
Procedure
Graphic Display – Service folder
Turn ON the check
in box will activate
the Notification
Warning to change
the consumable
parts such as Air
Filter, Oil Filter, Oil
and Demister or Oil
arrester
Graphic Display – Service folder
Press Clear button to reset Service Notification of
consumable parts
 START UP PROCEDURE
1. Open the cooling water supply valves if
applicable
2. Turn ON the power of CMC control & motor
Starter panel
3. Wait until the oil temperature reached above
95 Deg. F and indicates “Ready to Start” in the
LCD display
4. Open the first isolation valve
5. Press start button to run the compressor
6. Press load button to operate the compressor
on auto dual or modulate
 STOPPING PROCEDURE

1. Press unload button to shift into unload mode

of operation
2. Press stop button to shut down the
compressor
3. Wait for 30 minute to cool down the CENTAC oil
system then turn off the CMC control panel
and water supply valves
4. Close the first isolation valve
START & STOP SEQUENCE
MAINTENANCE
 MAINTENANCE

Daily and Each Start-Up

1. Check and record instrument air pressure.

2. Check the compressor reservoir oil level.
3. Check and record the oil temperature to the compressor.
4. Check and record the compressor oil supply pressure.
5. Check the vibration level on each stage of the compressor
6. Check and record all interstage pressures (if available).
7. Check and record all interstage temperatures.
8. Check and record the inlet air temperature (if available).
 MAINTENANCE

Daily and Each Start-Up

9. Inspect for tubing/fitting leakage.

10. Check and record the air cooler water temperature, both to
and from the coolers (if available).
11. Check and blow down the condensate traps.
12. Check and record the inlet air filter differential pressure.
13. Check to make sure the air coolers are continuously venting.
Vent valves are located on top of the casing.
14. Drain the condensate from the inlet air line drip leg. Do not
open the valve with the compressor operating.
15. Drain the condensate from the discharge header drip leg.
16. Drain the condensate from the bypass air line drip leg.
 MAINTENANCE

Daily and Each Start-Up

17. Drain the drip legs on any other horizontal run of air piping.
18. Check for oil leaks. Correct as necessary.
19. Inspect for gasket / o-ring leakage.
20. Check for water leaks. Correct as necessary.
21. Open the control air line drip leg valve to remove any
moisture that may have collected.
22. Check the instrument air line filter. Drain any moisture,
which may have collected.
23. Check and record the oil filter differential pressure, if
available. Replace the filter element as necessary.
 MAINTENANCE

Quarterly Maintenance

1. Inspect instrument air filter.

- Drain and clean the filter.
- Replace the element.
2. Drain control air drip leg.
3. Inspect condensate traps.
- Remove and clean. Replace parts as necessary.
- Replace trap if necessary.
 MAINTENANCE
Quarterly Maintenance

4. Visually inspect the inlet air filter.

- Clean element and replace as necessary.
- Inspect seams of the filter for cracks for potential bypassing.
Seal seams as needed.
5. Change oil mist arrestor element.
- Add oil to U-tube.
- Clean element housing.
- Inspect old element for over-crushing.
- Eliminate lock washer under wing nut, if installed.
- Replace seal washer under wing nut.
- Check to insure the element cover is making good contact with
the element. The cover should fit squarely on the housing.
 MAINTENANCE

Quarterly Maintenance

6. Inspect the Mist Eliminator element and replace as needed.

Mist Eliminator elements are a long life item and should not
require routine replacement.
9. Inspect control panel.
- Watch for: loose wiring, wrong line filter, damaged line
filter, and adequate arc suppressors.
- Clean panel fan filters and panel.
- Disconnect and tie back all unused wires from terminal
strips.
- Check the vibration transmitter wires to make sure they run
directly to the microcontroller terminal strips.
 MAINTENANCE

Semiannual Maintenance

1. Follow the quarterly schedule.

2. Lubricate the main driver coupling. Dry-type coupling
components must be inspected.
3. Change oil filter.
4. Leak test the air coolers.
5. Change the driver bearing grease.
6. Obtain an oil sample and have it analyzed (see Technical Flyer
in Appendix).
7. Check the control system per the procedure found in the
Control section of the Operation Manual.
8. Check the inlet and bypass valve calibration.
 MAINTENANCE
Annual Maintenance

1. Inspect the main driver per the manufacturer's instructions

found in the Operation Manual.
2. Visually inspect the coupling. Lubricate as required.
3. Manually rotate bullgear to feel for roughness on models with
bullgear anti-friction bearings. Check bullgear axial clearance of
maximum tolerance of 0.040” for journal bearings
4. Inspect and clean the oil reservoir suction screens. Clean
during oil change, if oil need to be change.
5. Visually inspect the oil cooler tubes. Clean the water side of
the oil cooler if necessary.
 MAINTENANCE

Annual Maintenance

6. Visually inspect the zinc anodes (pencils) in the oil cooler.

Replace if necessary.
7. Visually inspect the inlet throttle valve.
8. Visually inspect the bypass valve.
9. Visually inspect the discharge check valve.
10. Change the oil once a year or after 8,000 hours of use, unless
Techtrol Gold III is used. When using Techtrol Gold III, the
lubricant must be changed every three years / or after every
26,280 hours of use.