Installation Guide: Centac

CENTACÒ
Installation Guide
INGERSOLL-RANDÒ
AIR COMPRESSORS
INSTALLATION GUIDE
Copyright Notice
Ó 1992, 1999 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.
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Date of Issue: 18 March, 1999
INSTALLATION GUIDE
Table of Contents
Foreword____________________________________________________________ 1
Introduction _________________________________________________________ 2
Transporting the Centac Compressor ____________________________________ 2
Prior to Centac compressor arrival ___________________________________________ 2
Centac compressor arrival at the customer site_________________________________ 3
Off-loading __________________________________________________________ 3
Storing the Centac Compressor _________________________________________ 5
Up to 180 days' storage under controlled environment conditions _________________ 6
After 180 days' storage _____________________________________________________ 6
Storage under adverse conditions ____________________________________________ 6
Long-term storage _________________________________________________________ 7
Pre-installation meeting________________________________________________ 7
General Specifications for Centac Compressor Installation __________________ 8
The plant layout ___________________________________________________________ 8
The foundation ____________________________________________________________ 8
Leveling__________________________________________________________________ 9
Adjusting compressor package for level ______________________________________ 11
Grouting ________________________________________________________________ 11
Piping _____________________________________________________________ 12
The inlet piping___________________________________________________________ 13
The bypass piping ________________________________________________________ 15
The discharge piping ______________________________________________________ 16
The control air piping _____________________________________________________ 18
Expansion joints__________________________________________________________ 18
Parallel operation with reciprocating compressors _____________________________ 19
Cooling water ____________________________________________________________ 20
Condensate drains ________________________________________________________ 23
Instrument air ____________________________________________________________ 25
Compressor lubrication_______________________________________________ 26
Coupling greases ____________________________________________________ 29
Electrical connections ________________________________________________ 29
Installation check list_________________________________________________ 33
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INSTALLATION GUIDE 1
Foreword
This document is entitled Centac compressor Installation Guide. Its purpose is to provide
general and detailed procedures and information relative to the installation of the standard
Centac compressor centrifugal air compressor. Illustrations are included, where necessary,
for component and procedure clarification. These illustrations are not to scale and do not
include all actual part details. Certified diagrams that relate to the specific machine should
be consulted if detailed information regarding specifications and dimensions are required.
The procedures in this document are written for use by experienced mechanical
technicians, millwrights, or other similarly qualified work-persons.
This document does not purport to cover all details of variations in the Centac compressor
models, options added or modifications made during a specific machines lifetime. These
variations, options or modifications may cause some procedures to be inapplicable or out
of sequence. Where known the procedural variances required by the differences, options
or modifications are noted. Users of this document should be alert to the potential for
differences or inadequacies in procedures and alter the work sequence as necessary.
Nothing contained in this document is intended to extend any warranty or representation,
expressed or implied, regarding the products described herein. Any such warranties or
other terms or conditions of sale of products shall be in accordance with Ingersoll-Rand
standard Terms and Conditions for such products, which are available upon request.
PROPRIETARY NOTICE
This document contains confidential information. It is the property of Ingersoll-Rand
Company and is given to the receiver in confidence. The receiver by receipt and
retention of the document accepts the document in confidence and agrees that
except as authorized in writing by Ingersoll-Rand Company, it will not disclose to
others the confidential information contained herein.
Copyright Ingersoll-Rand Company 1997
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2 INSTALLATION GUIDE
Introduction
A properly installed Centac compressor operated in accordance with the manufacturer's
instructions will reward its owner with many years of dependable compressed air service. A
responsibility of the sales and service organization is to advise and assist an owner in the
proper installation and operation of the compressor.
This manual serves as a reference guide for proper Centac compressor installation. The
information it contains is general in nature and is applicable to most Centac compressors.
The Operation Manual, diagrams and prints provided with each compressor need to be
consulted for specific data and information applicable to specific compressors.
NOTE
Where found in this manual, the word must means that the specification must be met
to validate the Warranty. The word should means that it is a desirable condition but
not mandatory for the operation of the machine and failure to meet this specification
does necessarily affect the Warranty. Deviation from specification may severely limit
efficient operation or interfere with maintenance of the machine.
Transporting the Centac Compressor

The last manufacturing process for a new Centac compressor occurs at the departure
loading dock. At the dock the compressor receives a final inspection, is photographed
from four or more angles, and is prepared for loading and shipment. The entire
compressor is securely covered for the trip. Shrink wrap is used on some units and like
other methods, provides protection to the machine from the rigors of wind whip and
adverse environmental conditions during shipment.
Most Centac compressors are sold Freight On Board (F.O.B.) Mayfield. This means
that once the machine is loaded on the truck at the factory, Ingersoll-Rand no longer
has custody of the machine and the machine becomes the property of the customer.
Some Centac compressors are sold F.O.B. customer site. This means that the
machine remains the property of Ingersoll-Rand until such time as it arrives at the
customer's site.
The shipping company is responsible for damage-free delivery from the time the
compressor is loaded on the truck at Mayfield until it arrives at the customer
destination, unless there is some special circumstance.
Prior to Centac compressor arrival

Many things must be known prior to the Centac compressor arrival on site. Some of
the most important of these things are:
a. Will the machine be started within 180 days from the date of shipment from the
factory?
b. Where will the machine be stored and what ambient conditions will it be
exposed to while it is in storage?
c. What storage procedures will be implemented?
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Centac compressor arrival at the customer site

The customer must be made aware of the necessity to conduct an arrival on site
machine inspection. If the machine was shipped F.O.B. Mayfield it is a customer’s
responsibility to discover any transportation caused damage and submit any claims to
the shipping company. It is highly desirable and recommended that Ingersoll-Rand
representatives be on site to assist the customer in the performance of the arrival
inspection and any damage assessments.
If the machine was shipped F.O.B. customer site, it is Ingersoll-Rand's responsibility to
insure that any transportation damage is recorded for damage claim purposes.
The arrival inspection ideally occurs while the machine is still on the delivery truck. The
arrival inspection should include the following:
a. Be particularly aware of the vibration probes, RTD’s, valve positioners, actuators
and other components that "stick out" and which could have been damaged in
shipment.
b. All gauge glass or other components covered by glass or plastic (if any) should
be intact.
c. Insure that the coupling spool piece, coupling bolts and nuts, gaskets, spacers
and o-rings are received.
d. Paint should be intact with no rust or other deterioration visible.
e. Check for obvious major or minor damage.
f. Compare shipping documents with all the material received.
If discrepancies are found, insure these are recorded and reported in accordance with
the shipper's procedures. The customer must be involved in the report and claim
process if the machine was shipped F.O.B. Mayfield.
In general, and except for the F.O.B. customer site situation, the customer will have to
purchase any new replacement components or parts, since the warranty does not
cover damages received in shipping. Customer reimbursement, if any for these costs,
would come from the shipping company. Ingersoll-Rand service personnel normally
repair any damages sustained in shipment. Knowing the nature and extent of damages
by assisting in, or performing the arrival inspection, will help in expediting any repairs.
A plan for repairs or replacement of damaged components should be known before the
sales or service person departs from the customer's site. Contact Aftermarket and/or
the Customer Service Department as necessary to obtain parts and materials.
Off-loading
Use care during unloading to assure safety and avoid damage to compressor
components. Damages that occur during the unloading operation are the customer's
responsibility. Ingersoll-Rand is responsible for the unloading only in the event that this
had been specifically contracted for in the terms of the sale.
The CV series and 0CV model machines have lift truck fork openings provided in the
base for lifting purposes. These are shown in Figure 1 at point A for the 1CV. The 0CV
has similar openings. The lift truck openings are the preferred lifting points. The lift
truck openings can be used with slings as well as fork truck lifting. An alternate lifting
point for lifting with rigging is shown at B in Figure 1. The rigging must go through both
casing ribs and under the motor flange.
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Machined Surface
CEN T A C
IN G E R S O L L -R A N D
A
Figure 1
Centac compressor 1CV lifting fixtures
WARNING
Never use the installed eye bolts to lift the entire machine because they will not
support the machine's weight. Eye bolts are designed to lift the component part to
which they are attached. Only those slings that have known strength should be used
for lifting. Using untested slings is hazardous. Heavy lifting involves skill. Only
qualified and experienced people should undertake the task of lifting a machine.
Failure to observe these precautions can result in severe injury or death.
Specific weight data for specific compressor units is found in the blueprints and Operator's
Manual for the unit.
Provisions for lifting or moving have been incorporated in all Centac compressor models.
The lifting provision on Centac compressors other than CV and 0CV are usually round
holes that pass through the machine base structural members.
The lifting openings are near the extreme ends of the base for best weight distribution
during lift. Spreader bars are required when lifting as shown in Figure 2.
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Figure 2
Typical Lifting Arrangement of Larger Centac compressor Frame sizes
Storing the Centac Compressor

Often a compressor will be off-loaded to a temporary storage location such as a
warehouse, or may even be left out-of-doors pending final placement. Wherever the
machine may be located, it is essential that it be protected from the adverse effects of
weather and other conditions. The greatest problem that affects the stored Centac
compressor is corrosion. The type of corrosion of greatest importance is oxidation caused
by moisture in the air. During storage, using correct procedures can eliminate iron oxidation
(rusting). These procedures will minimize or eliminate other adverse effects of storage such
as electrical equipment deterioration.
The basic warranty period on Centac compressor is 18 months after shipment or 12
months after being placed in operation. The warranty specifically excludes the effects of
corrosion, erosion, and normal wear and tear.
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Up to 180 days' storage under controlled environment

conditions
The compressor, as it comes from the factory, can be stored in a controlled environment
for up to 180 days after shipment with no special storage action being required. A
controlled environment means storage in an enclosed building at a constant and uniform
temperature. Customer Service should be consulted for procedures to follow in the event of
adverse environmental storage conditions. Adverse here means, compressor stored
indoors but may be subjected to uncontrolled temperature and/or humidity. The unit should
be started up within the first 180 days after shipment to assure full 12 months warranty.
After 180 days' storage

If the compressor will not be started within 180 days of shipment, the compressor must be
inspected to receive the 12 month warranty. This inspection must be done by an
authorized person and may involve an actual tear-down of the machine. The tear-
down may be called for in some cases to enable accurate assessment of conditions. The
compressor is prepared for another 180-day period; if this second or subsequent period is
exceeded before start-up, the inspection process is repeated. The customer, normally,
bears the cost for the inspection service and any parts requirement.
This warranty extension may require some or all of the precautions listed below under the
adverse condition paragraph to be taken.
Storage under adverse conditions

The warranty does not cover damages resulting from adverse storage conditions.
Precautions must be taken to assure that the machine is protected from the
elements. The specific precautions to take will vary from site to site. Moisture and dirt
must be kept from contaminating the machine internals. Preventing corrosion particle
buildup (rust) in the machine internal areas is the primary goal of the adverse storage
condition procedures.
A key to corrosion prevention is to maintain a constant temperature. If there are wide
swings in ambient temperature over a short period of time, there is a tendency for
condensate to form inside the compressor. This natural condensate can accelerate
corrosion build-up and cause potential damage to electrical components. To minimize the
effects of temperature changes, insure desiccant bags are renewed and all openings to the
compressor internals are tightly covered. Place a lighted 100 watt incandescent lamp in the
control panel to maintain a constant or elevated above ambient temperature.
In construction areas, where there is an abnormal amount of dust and dirt in the air, it is
advisable to keep the entire compressor covered. Be aware that a tightly fitted waterproof
cover over the compressor may trap moisture inside and cause more harm than good. Air
circulation with no dirt accumulation is the desired result.
Under extreme conditions of dampness or dirt, any or all of the following may be necessary
to protect the compressor. Exactly what should be done will depend on the circumstances.
a. Bleed (purge) dry nitrogen gas through the machine to absorb and displace moisture
and eliminate free oxygen for corrosion reduction purposes.
b. Provide for desiccant bag replacement or installation of desiccant bags in various
areas.
c. Energize motor space heaters (if provided) while in storage.
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d. Manually spray the compressor bullgear and pinions with compatible rust inhibitor
oil.
e. Provide an energized 100 watt lamp in the control panel to drive off moisture.
f. Place machine in long-term storage.
Long-term storage
If the unit will not be started within 180 days after shipment, the long-term storage option
should have been ordered from the factory. Under the factory long-term storage option, the
compressor is shipped with the rotating assemblies removed and packed in corrosion-
inhibiting material. Other special precautions are taken with the internals of the machine.
An authorized Ingersoll-Rand technician is required to supervise or actually clean protected
parts and reassemble the machine.
Long term storage procedures are detailed and specific. These procedures are available
from the Centrifugal Compressor Division. The terms of sale for the specific machine put
into long-term storage contains information relating to who will or has paid for the cleaning
and reassembly.
Pre-installation meeting
The Area Manager will normally have had numerous discussions with the customer or the
customer's contractor concerning the optimum site conditions for Centac compressor
operation. Prior to the planned start-up day, a service visit for an on-site pre-installation
review is recommended. The Area Manager will normally conduct a pre-installation meeting
with customer personnel and do a pre-installation inspection.
The primary goal of the pre-installation meeting is to insure that all concerned have a clear
understanding of the importance of proper installation to the lifetime of the compressor and
to clear up any areas of uncertainty regarding the mechanics of installation.
The service visit can assist the Area Manager and customer by bringing to their attention
any installation details that may have been overlooked. Site information that will assist the
service organization in determining site readiness for the start-up can be obtained at the
same time.
There are few hard rules concerning exactly what constitutes an unacceptable installation.
The Centac compressor engineering staff has developed specifications and
recommendations that insure that all requirements for efficient, dependable operation are
met. Failure to meet some of these requirements does not necessarily mean that the
installation is unacceptable from a machine-safety or ability-to-operate position. Failure to
fully incorporate all the specifications and recommendations for installation will degrade the
efficiency, dependability or other potential of the machine in some or all respects.
When certain specifications for the Centac compressor installation are not met, the
warranty on the machine will be in question. It is a Customer Service Department
responsibility to review the specific situation and authorize a deviation from these
specifications so that the full warranty will remain in effect, or to advise that the warranty is
void and that Ingersoll-Rand can have no responsibility for the machine.
The deviation from specification authorization will not be given in any case where there is
any question regarding the ability of the machine to operate properly or safely. In the
extreme case, a Waiver of Liability, Ingersoll-Rand Form 83084 Revision 1, is completed
when the customer insists on starting a machine where mandatory installation
specifications have not been met.
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The service representative and Area Manager have a responsibility to insist that the
customer incorporates all specifications and recommendations for the Centac compressor
installation. The overall life of the machine in large measure depends on proper installation.
General Specifications for Centac Compressor

Installation
The specifications for each individual machine are contained in the Operator's Manual, in
the form of drawings or other documents provided with each machine. Consult these
references for specific information relating to a specific machine installation.
The plant layout

A well-designed installation will result in lower installation and operating costs. Operation
and maintenance personnel will generally give better attention to a compressor that has
been installed with good planning and consideration for all the various needs.
The Centac compressors location within a plant facility is very important. The compressor
should be located in an area that is accessible to operators and maintenance personnel. It
should be in a climate controlled environment (heated building) if it has not been
specifically designed for outdoor use. The Centac compressor can best be handled with
overhead crane facilities for installation and maintenance. An overhead rail with chain hoist
or crane will simplify removing the largest component parts, if and when it becomes
necessary to inspect or replace them. Overhead lifting facilities should be included in the
installation.
Ample space should be provided in all directions to permit easy handling during installation
and later maintenance. Floor space should be provided so compressor parts may be laid
aside during any tear down for inspection or repair of the rotating elements and other
internal parts.
A Centac compressor should be installed where it is easily accessible for observation and
maintenance. In elevated locations or in pits, there should be stairways, catwalks, or other
provisions for easy access to the machine.
Ventilation around the machine is important. Provisions for clearance limitations given
on the General Arrangement drawing must be met and adequate ventilation must be
provided. On electric motor driven-machines, the heat radiated into the room’s air will be
approximately 6% of the total horsepower. (1 HP = 42.4 BTU/min. = 10.68 kCAL/min.). In
areas where noise could be a problem, steps should be taken in treating hard reflective
surfaces in the area. Installing the unit in an area with low hard ceilings and walls should
be avoided.
The machine should not be installed in a damp or dusty atmosphere or where corrosive
vapors may enter the compressor or the driver. Dust buildup in a motor's ventilation
passages will shorten the motor's lifetime by reducing the heat transfer from the motor
windings to the ventilation air. Damp and/or corrosive atmospheres will quickly deteriorate
control and driver insulation causing premature failure.
The foundation
Proper foundation design requires an intimate knowledge of local conditions. The user
assumes full responsibility for an adequate foundation. It is strongly recommended that
those who have experience with machinery foundations provide foundation design.
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The Centac compressor foundation need not be massive but must be able to support
the weight of the unit. There are no out-of-balance forces in the Centac compressor like
those that are encountered in a reciprocating compressor. All loads from the Centac
compressor can be considered as static loading on a foundation.
The foundation must be constructed in a manner that assures that vibrations from
other sources are not transmitted to the Centac compressor.
For the Centac compressor family of packaged compressors, a simple concrete pad or
steel support is recommended for each compressor. It is recommended that the concrete
pad be level and flat so that the bottom of the baseplate is in full contact with the pad.
Anchor bolts or similar fixtures are required to hold the compressor in place. Most
construction codes and federal OSHA requirements mandate hold-down fixtures for all
machinery.
The base-plate footprint and foundation hold-down configuration is shown on the drawings
provided for each machine.
Leveling
Driver, compressor, and base levels are important for the following reasons:
a. If the machine is not level longitudinally, the starting and stopping weight of the
driver rotor will bear on the thrust bearings (uphill or downhill), resulting in possible
premature wear.
b. The same force will burden the compressor bullgear thrust bearings and put stress
on the coupling.
c. If the level is off, the oil sump level, demister function and the coolers high point
venting could be affected.
d. Motor bearing lubrication and lubrication drain-off could be affected resulting in
possible premature failures.
e. Proper drainage of condensate and general pipe fit up could be affected by an out-
of-level condition.
Before level readings can be taken, the compressor must be resting on the foundation pad
in its final position with the anchor bolts (or nuts) snug. If it is known or suspected that the
pad is not level, shims or wedges can be installed at the anchor bolt positions when the unit
is set in place. Level condition is determined by using a transit level, machinist level, or
other higher-technology means.
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Figure 3 shows the markings on a typical 12-inch level. These markings are normally
0.0005 inches per foot marks. An off-level reading of 0.001 inches per foot is shown in
Figure 4, more markings than shown exist on an actual machinist's level.
0.0005 inches/foot 0.001 inches/foot
Machinist's Level Machinist's Level
Figure 3 Figure 4
Dimension marking Off level reading
On 0CV, the level reading is taken on the top face of the compressed air discharge flange.
The specification for level of 0CV is 0 to 1/16 inch per foot (0.0625 in/ft) or (0.494 mm/m).
Figure 5 shows location of the machinist level when level measurement is taken on 0CV.
CV0 is leveled from the discharge flange
CEN T A C
Figure 5
Centac compressor 0CV level placement point
On the 1CV and 2CV models where the driver is flange-mounted, the level measurement is
taken on the machined surface where the compressor mounts to the base. Scraping off
paint to expose a bright metal surface is not required to take level readings. The painted
surface normally provides a sufficiently smooth surface for level measurements. Figure 1
shows the location for taking level on a model 1CV. The same location is used on model
2CV.
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The level specification for model 1CV, 2CV, and all Centac compressor models other than
0CV is 0 to 0.1 in/ft (0 to 7.3 mm/m).
The preferred method to determine level is with a transit level, since it easily measures the
entire length rather than a section at a time like the machinist's level.
When a machinist's level is used on the long base-plates of the model C, CII, and other
models, readings are taken on the machined surfaces on the base. Measurements are
taken from side to side and lengthwise working down toward the opposite end of the base.
Adjusting compressor package for level

Shims or wedges are placed at each side of each of the anchor bolts and adjusted until a
level is achieved. Figure 6 illustrates the use of wedges and shims.
Wedges are the preferred adjusting devices because they can be easily removed. Shims
serve the same function as the wedges but are difficult if not impossible to remove.
Anchor bolt
Baseplate
Leveling wedges Leveling shims
Foundation/pad
Figure 6
Wedge and shim placement
Once the machine is leveled within specifications, the anchor bolt nuts are snug tightened
with the machine resting on the wedges or shims.
Actual leveling is done with levers or jacks, whichever are available at the site. A rough
driver to compressor alignment should be done before any grout is poured. The rough
alignment check is to verify that no abnormal conditions exist which will interfere with the
precise alignment to be done after the grout has set.
The rough alignment position is achieved when the driver is within ±1/16 inch (1.5 mm) of
its final aligned position. When performing the rough alignment, verify that there is room for
final alignment movements between the motor and the anchor bolt in the bolt bore in the
motor feet. An insufficient clearance between anchor bolt and bolt bore will prevent final
alignment. This problem, if it exists, is eliminated on a case basis by making the bolt bore
larger.
Grouting
Grouting forms are prepared and grout is poured after level has been verified. When the
grout has set up, the wedges or shims are removed. The void space left in the wedge or
shim area is then back-filled with grout. If the wedges or shims are not removed, corrosion
will upset the level at a future time. A nut used on the underside for leveling of the base is
not recommended because it too will corrode over time and upset the level.
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Grouting serves two significant purposes. The first purpose is to provide full area support
for the machine's weight-bearing base structures. The second purpose is to provide the
means of support when a machine needs to be leveled. There are other non-structural
purposes for grouting which have to do with housekeeping.
Epoxy grouts are recommended because they have proven to be superior to the mortar
based grouts, although they are usually more expensive. Epoxy grouts are not affected by
spilled lubricants, are easy to clean and present a neat appearance. Mortar grout does not
have these advantages.
For Centac compressors with flange-mounted motors (1CV, 0CV, 3CH, 4CH, 2CV, etc.),
no base grouting is required as long as there is full base-plate support contact with the pad
and the machine is within the specification for level. On these machines there is little
flexibility possible between the compressor and the driver. The drive and driven shafts are
aligned by the flange that rigidly holds the two together. Grouting this configuration serves
no structural purpose and is not necessary as long as the base is supported and level.
Grouting does enhance the ease of housekeeping and overall appearance of the
installation. The exception to this is when the foundation pad is not level. In this instance
grouting the base to a specified level plane is required.
The supporting surfaces (underside) of all the various Centac compressor baseplates are
not machined surfaces. The small imperfections in these surfaces relative to a "machined
surface" are insignificant regarding the ability to support weight. Similarly the small
imperfections in a "smooth" concrete surface are insignificant in terms of its ability to
support the compressor weight.
A simple but adequate method of determining if the base-to-pad mating surface is
satisfactory is to shine a light from one side to the other. If undiffused light can be seen, the
surface is too rough and grouting is needed. Regardless of which surface is rough, the
corrective action is to install grout.
For Centac compressors without flanged drivers (C series, CII series, X-FLO and the larger
CHs) grouting of the baseplate support is required. Grouting should be done on all Centac
compressors that have foot mounted coupled drivers. If it can be shown that the base
supports are in full contact with the pad and the base is within the specification for level,
grouting is not required. This is very difficult to determine in the large machines because
support is provided by structures that are hidden from view. Grouting insures that all
support areas, visible or not, are providing the support intended.
Piping
Centac compressor products have no design provision for accepting the full weight of
external piping connections. The discharge, inlet, bypass, water and other piping
connected to the machine must be self-supporting. Piping alignment to the
compressor mating flanges is essential, but strains on the casing must be avoided.
See Table 1 for general pipe size specification data.
Pipe strains have three sources: (1) Dead weight of the pipe, (2) Expansion or contraction
of piping as it undergoes temperature change and (3) Pressure within the pipe. These
sources are considered in any engineered pipe design.
In the practical sense, if any pipe needs to be levered or pried into position to match up the
flange face with the compressor, there will be excessive pipe strain. A properly matched up
pipe flange will have just enough space to slip in a gasket, will allow all flange fasteners
(bolts, studs, etc.) to pass through the flange bolt bores without adjustment of the mating
flanges, and does not twist in any plane when the fasteners are tightened.
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All piping connected to the Centac compressor should have provisions for compressor
maintenance. This usually means that there are flanged sections or unions in the
connecting pipe. Failure to make provisions for repair will result in difficulty during
disassembly. A sufficient number of removable sections of pipe should be provided to
allow ease of maintenance and repair.
Numerous customer-provided piping connections are required to make the Centac
compressor operational. These connections are the inlet piping, the discharge piping, the
bypass air piping, the cooling water and casing vent piping, the instrument air (IA) piping,
the condensate drain piping and the control air (CA) piping.
The inlet piping

The inlet air system must be constructed in a manner that meets the compressor
performance requirements. The general requirements are the same for all Centac
compressors. See Figure 7 below, inlet piping system.
Inlet filter
Work platform
p
8 ft. min.
Roof line
Max p 0.3 psig (2.1 kPa)

Entire pipe to be
non-corroding material Pipe hangars
Inlet air temp Removable

transition piece
Long radius elbow

Inlet valve
Minimum of 4
Low point drain pipe diameters
Figure 7
Model inlet pipe with filter
The inlet air and the bypass piping systems on the 0CV, 1CV, 1CVA and 1CVB that have
integral aftercoolers are built in and are provided as part of the compressor package. The
factory packaged systems meet the same general requirements as the larger external
systems that are installed by the user.
The specific components used in the various inlet air systems vary in design and degree of
function. For instance, the filter used on a 0CV looks nothing like an absolute filter that may
be found on a 5CII. A basic filter is required on all Centac compressors and it is customer
preference, compressor size or site need that dictates specifically what type of filter is
installed. It is the intent of this manual to provide a knowledge of system requirements
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without describing in detail all of the variations of the system. During the installation
process, it is the salesperson's task to insure that the requirements for compressor
operation are met, that any optional components are properly added and applied in the
system, and that the compressor is capable of performing its function to the user's
satisfaction.
The basic inlet filter system must be capable of removing 98% of all particles larger than
4 microns (1 micron = 1 millionth of a meter = 1 x 10-6).
The filter installed on the CV and 0CV packaged units are not suitable for use on extended
inlet pipe or in out-of-doors installations. They must not be used in this manner. An
optionally available filter and housing is used in these cases.
The inlet filter should be located where it will not be subject to ingestion of emissions from
plant exhausts, cooling tower vapors and other similar sources. Small amounts of acid
forming gases, like SO2 in the inlet air, are magnified in the compressor causing damage.
The desired filter location is upwind of emission sources in the prevailing site wind pattern.
The combined pressure drop across the filter and pipe must not exceed 0.3 psi (2.1
kPa).
Adequate piping supports are necessary to prevent excessive dead weight loads or strains
on the compressor flanges. Questions regarding pipe construction and strain are best
answered by qualified mechanical design personnel.
The inlet pipe is to be constructed of a non-rusting material such as stainless steel,
aluminum, laminated fiberglass or heavy gauge CPVC. The pipe should be suitably flanged
so that pipe cleaning can be done in sections as well as for providing maintenance on the
machine. Removal of large components is sometimes hampered by piping that cannot be
easily removed. The inlet pipe must be inspected and its cleanliness verified prior to
startup. Anything that is loose in the pipe will end up in the first stage and most assuredly
will cause damage.
a. Epoxy-coated carbon steel pipe should not be used. These pipes are subject to
epoxy unbonding with the detached pieces of epoxy subsequently entering the
compressor and causing damage. Using epoxy-coated inlet pipe is not
recommended.
b. Rust and corrosion that occurs in an uncoated carbon steel pipe will cause damage.
Bare carbon steel pipe is not acceptable and must not be used.
c. CPVC pipes have been known to shatter as a result of shock in extreme low
temperatures. Using CPVC pipes is not encouraged but its use is not prohibited
since CPVC pipe of correct strength and dimension has been used successfully
in many installations.
d. Fiberglass pipes are subject to delamination and have been known to damage
compressors. Using this material is not encouraged but its use is not prohibited
since fiberglass pipe of correct strength and dimension has been used very
successfully in many installations.
e. Welded stainless steel or aluminum are the best inlet pipe choices. Whatever is
used, the customer is responsible for inlet pipe selection, design, installation and
cleanliness.
Regardless of which acceptable material is used for the inlet pipe, it must be of the
correct strength and size. Minimum acceptable general pipe sizes are given in Table 1.
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The applicable compressor installation instruction should be consulted if there are any
questions regarding size of inlet pipe.
To stay within the 0.3 psi drop criteria the inlet pipe is always several pipe sizes larger than
the compressor inlet flange size. Example: A C12 with a 28 ft run of inlet pipe would have
10 inch pipe attached to the 6 inch inlet flange and a C12 that has a 50 ft run would
nominally be made up with 12 inch pipe attached to the 6 inch compressor flange.
Transition pieces that go from one size pipe to another will be required. Transition pieces
should have a gradual taper. See removable transition piece in Figure 7. Rules of thumb
abound for sizing pipe, these rules should not be relied upon. The inlet pipe must be
engineered for all Centac compressors with non-attached inlets.
Long radius elbows should be used. Sharp bend elbows cause high pressure drop and
turbulence in the inlet air and compressor performance can be significantly degraded.
The inlet pipe should be a short and direct run to produce minimum pressure drop, any
horizontal run of pipe should be installed with some slope so that any condensation in the
piping will run away from the compressor. Drains should be installed at all low points in the
horizontal runs of pipe.
In fiberglass or CPVC pipe insure by thorough inspection that no delamination or glue
globules exist that may detach and foul the impeller. A thorough inspection is also
necessary in welded pipe because weld slag on the pipe internals can detach.
The inlet pipe must be absolutely free of foreign matter.
The bypass piping

The bypass piping handles the blow-off (bypass) flow of the compressor when it is
unloaded or running below the minimum throttle point. See Figure 8.
As with the inlet pipe, any pipe-induced strains on the compressor must be avoided.
The bypass pipe must be supported by suitable hangers.
A silencer is normally recommended and installed in the bypass pipe. If the silencer is to be
mounted in the horizontal position, a drip leg should be installed. Drip leg points are
provided on the silencer.
The pipe located after the silencer should be sized to insure that the back pressure seen
by the silencer is no more than 5 PSIG (35 kPa).
To achieve the best sound attenuation in the bypass system, use a straight horizontal run
of pipe from the compressor, approximately 8 pipe diameters long, before adding a long
radius elbow that leads to the silencer. The silencer should be kept as close to the
compressor bypass valve as possible and the total length of the pipe-line kept short. To
further reduce noise the bypass pipe is lagged.
To reduce maintenance time and facilitate removal of heavy casing parts the pipe should
have flanged sections.
A low-point drain should be installed in all horizontal pipe runs at low points to drain off any
condensate that may accumulate in the pipe.
Although both the inlet and bypass pipes should be as short as possible, bypass air
discharging into the atmosphere should not be near the inlet if the location has a tendency
to collect dust and debris. A large volume of air will discharge from time to time from the
bypass. This volume can blow dust, dirt, stones and other non-attached materials into the
inlet. On units without integral aftercooling, the bypass discharge will be very hot and
suitable guards should be installed.
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To prevent ice, snow or other foreign matter from entering the bypass piping, the end of the
pipe should be necked over. Expanded metal should cover the opening to block animals
or other foreign objects from entering the compressor.
Discharge deflector
Roof line
Hanger (typ)
Silencer
Alt. side wall discharge

Long radius elbow
Drain
Bypass valve
Figure 8
Model bypass pipe
The discharge piping

The discharge pipe should be, at least, the full size of the compressor discharge
connection. Where pipe diameter conversion is necessary, the transition in size should be
gradual. The use of long-radius elbows is recommended. Figure 9 illustrates the general
requirements for the discharge pipe.
A block valve should be installed in the discharge line to prevent backflow through the
compressor in the event of a check valve failure and to facilitate any repairs on the
compressor.
A safety valve (required by many construction codes) is installed when required between
the check valve and the block valve to prevent over pressurization of the discharge system.
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Block valve
Safety valve
Pipe support
CA tap in. To be located

Discharge temperature a minimum of 10 pipe diameters
from check valve in
non-turbulent flow area.
Discharge pressure Non-rusting control air line.

Connects to control panel at
connection marked CA
Maintenance flange
Long radius elbow

Compressor
mounted
check valve
Low point drain
Figure 9
Model discharge pipe
A thermometer and pressure gauge should be installed in the discharge line to facilitate
troubleshooting and to provide backup information.
Piping supports are required to prevent excessive strain (dead weight loads) on the
compressor flange. As with all pipes connected to the compressor, provisions should be
made to make any alignment changes in the piping and not the compressor.
Check valves in the discharge piping must not isolate the control air (CA) sensing
points of compressors that are intended to run in parallel. Check valves installed in the
wrong location will cause the parallel running compressor pressure control system to be
unresponsive to changes in system pressure.
If one compressor (#1) has a slightly higher discharge pressure than second compressor
(#2), the check valve downstream of #1 will close. This check valve closing will prevent the
CA of #1 from sensing header pressure. In this event, the #1 compressor controls only the
pressure in the pipe between its CA line and the downstream check valve. Attempts to
control the header pressure in this situation by setpoint pressure manipulation results in
switching the no-control problem from one machine to the other.
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When the check valves are correctly positioned, both compressors will sense the header
pressure. Compressor #1 and #2 will each react to a change in header pressure when
check valves are correctly positioned.
Downstream check valves in parallel running compressor installations must be located so
they will not interfere with the compressor control pressure sensing (CA) ability.
The control air piping

The control air (CA) pipe penetration is made at a minimum distance of 10 pipe diameters
downstream of the discharge check valve in the discharge pipe. See Figure 4. The control
air line connects to the control panel connection marked CA. The line should be
constructed of 1/2 inch (12.7 mm) minimum, non-rusting material. If the control air line is to
be installed in a horizontal run of the discharge pipe, it should be located at the top of the
pipe to minimize condensate or debris buildup in the CA line. Drain provisions should be
made at the CA line low points. A filter in the CA line is not recommended because of a
filter's inherent pressure drop. There is no air flow in the CA line and a filter serves no
purpose in this situation.
Expansion joints
Centac compressors that have hot air discharge (no integral aftercooler) will normally be
fitted with expansion joints at the compressor discharge and bypass flanges. Various types
of expansion joints are used.
NOTE
It is important that expansion joint installers consult the manufacturer's installation

bulletin to assure correct placement.
The common type of expansion joint used on Centac compressors is designed for thermal
axial expansion of the pipe only, see Figure 6. An expansion joint compresses to absorb
the growth of pipe, requiring that the pipe be anchored to prevent growth away from the
joint.
The heavy inline arrows in Figure 6 show the directions of anchored pipe growth. The pipe
must have support hangers and growth guides. It requires special knowledge to
properly apply these supports, guides and anchors in a system.
Expansion joints normally have shipping and movement prevention rods attached. The
shipping rods prevent compression or expansion of the joint prior to its installation in a pipe
system. These shipping restraints must be removed prior to operation of the joint in
the system.
Retainer rods or other features are provided to prevent uncontrolled joint expansion, which
can easily occur if the pipe is not properly anchored. Expansion joints are not intended to
absorb pipe misalignments and will fail if used for this purpose.
Expansion joints must be used on turbine drive steam inlet and steam exhaust
piping to prevent compressor base movement.
The need for proper expansion joint installation and operation cannot be over
emphasized. They must be installed correctly.
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Anchor
Anchor
Pipe support/guide
Pipe support/guide
Expansion joint bellows Retaining rod
compressor casing
Figure 10
Model expansion joint installation
Parallel operation with reciprocating compressors

It is essential that the system into which a single or multiple Centac compressor installation
will discharge will not upset the dynamic nature of the machines. The pulsation's from
reciprocating air compressors (if not dampened) will effect the Centac compressor
discharge and control system in an adverse manner and cause the Centac compressor to
surge, not share the load, or cycle up and down and possibly back completely out of the
system. Depending on critical pipe lengths, the pulsation's can be amplified to the extent
where discharge check valves are damaged. Once this damage occurs, the potential for
destructive reverse rotation, as a result of reverse air flow through the Centac compressor,
increases considerably.
See Diagram 2. A Centac compressor must not be piped directly to the same header
as reciprocating compressors. In the event the Centac compressor discharge is
paralleled with reciprocating compressors, the discharge is routed through a receiver or
installed downstream of pulsation dampers.
The receiver will dampen out the pulsations from the reciprocating compressor discharge.
Pulsation dampers on reciprocating compressors perform a similar function.
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CENTAC ON LINE WITH RECIPROCATING COMPRESSORS
CA
System
CENTAC
CA
Receiver CENTAC
Recip.
Recip.
Diagram 2
Cooling water
The cooling water system provides the media to cool the compressed air in the air coolers
and the lubricating oil in the oil cooler. Compressors designed to have interstage cooling
will exhibit a significant reduction in performance if cooling is not adequate. All Centac
compressors require lubricating oil cooling. Catastrophic damage will occur if lube oil
cooling does not occur. The heat that the cooling water system carries away represents
waste energy that results from the heat of compression, friction and other mechanical and
electrical losses in the machine.
Ideally, pure water is the choice cooling media, but this is not a practical requirement and a
specification range has been established. The cooling water provided to the Centac
compressor should be soft, clean and free of corrosive elements as indicated by the
specification listed below. The water should be treated and filtered so that it falls within the
specified ranges.
a. Total hardness expressed as CaCo3 should be less than 100 PPM.
b. The acidity should be within 6.0 pH to 8.0 pH
c. Suspended solids should not exceed 50 PPM.
d. The Langelier saturation index should be within a range of +0.5 to +1.0.
Langelier's Index is a technique of predicting whether water will tend to dissolve or

precipitate calcium carbonate. If water precipitates calcium carbonate, scale formation may
result. If water dissolves calcium carbonate, it has corrosive tendency. Factors other than
those measured by Langelier's Index contribute to corrosion or deposit formation. These
factors include temperature differences within a system, changing operating conditions or
the presence of chemical treatment in the water. The presence of dissolved oxygen in the
water may cause water with a "zero" Langelier's Index to be corrosive rather than "neutral".
The chemical composition of the cooling water is a customer responsibility. Poor-quality
cooling water will reduce the performance and reliability of the compressor, increase
maintenance time and costs and in extreme cases may affect the warranty.
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It is recommended that a throttle valve (globe or ball valve) be installed in the water
discharge of the air coolers and the oil cooler. The throttles aid in temperature control.
Cooling water system problems such as high friction loss and noise are related to flow
velocity caused by inadequate pipe size. Elbows, valves and other restrictions will create
friction that increases the noise level. Almost all valves will cavitate when the flow rate is
great enough or when the valve is partially closed. Adequate lagging can reduce noise and
line silencers may be considered. In low pressure piping, the highest noise level is
generated on the downstream side of the valves.
In dirty water systems, a piping arrangement that will allow for backflushing the coolers is
recommended. Backflushing, in some cases, can be accomplished with the compressor in
operation but higher temperatures will result and high temperature shut down points may
be reached. If chemical cleaning is anticipated, a provision for chemical addition should be
provided. Chemical cleaning should be done when the compressor is shut down.
Diagram 3 shows a general back flush arrangement as well as other features of a cooling
water system.
O P TIONA L C OOL ING W A TE R S YS TE M B A CK FL US H
Flow ind ica to r

Inle t
D isc ha rg e V ent va lve
A ir c ooler
4 w ay bac k flus h v alv e
hot air
Tem per ature

Ga te
v alv es
P re ss ur e
ve nt lin e
Thro ttle v alv es

Ch em ic al c lea ning
flan ge s
O il c oo le r
* V alv es and g aug es n or ma lly s upp lie d by cu stom er
Diagram 3
Cooler backflush arrangement
Isolation gate valves should be installed in the cooling water inlet and discharge pipe line
for machine isolation purposes. Regardless of the type of cooling water system used, a
strainer should be installed in the water supply line.
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An optional water flow switch may be installed in the cooling water discharge pipe. The CV
has this switch installed as part of the packaged unit. On larger machines, the optional flow
switch is installed in the customer provided system. The correct type of boss, Weld-O-Let
or other discharge water pipe penetration must be used. The flapper motion in the flow
switch must not be restricted. Figure 11 shows a correct and incorrect installation of the
flow switch.
The flow switch must be installed vertically in a low profile boss with lead wires up and in a
horizontal run of discharge pipe. Three pipe diameters of straight run are required before
and after the flow switch to insure it will operate properly.
INCORRECT ATTACHMENT CORRECT ATTACHMENT
7/8" (22.2mm)
Low profile
Standard boss
Weld-o-let
Flow Flow
Paddle hits pipe
INCORRECT CORRECT
Figure 11
Flow switch indicator
Closed cooling water systems, especially in the cold climates, normally use a mixture of
Glycol (anti-freeze) and water. Glycol/water mixtures do not transfer heat as readily as
water alone. Coolant flow rates must be adjusted to accommodate the lowered heat
transfer capability in these systems. Many compressor overheat situations are traced
directly to an improper Glycol/water mixture. In general a 40% Glycol to 60% water mixture
is used. Appropriate engineering staff should be consulted in cases where improper
mixture or problems with design are suspected. The Glycol/water percentage amount is
measured with a Hydrometer or other more sophisticated test.
Casing vent lines are normally constructed out of tubing. Size varies from model to model,
but in general the 0CV, CV and models through 5500 ICFM use 1/4 inch (6.4 mm). Larger
machines have 1/4 inch (6.4 mm) vent lines.
If the casing vents are to be routed to an open drain, the vent termination should be visible
so that actual flow through the vent can be verified by observation. The vent should be
piped to the cooling water discharge through a flow indication device if a closed cooling
water system is used.
Casing vents not piped to the coolant discharge or floor drain should have their petcocks
opened by operating personnel on a periodic basis to vent off any gas pocket build up. If air
or gases are permitted to accumulate in the cooler casings, the coolers will overheat.
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Specific compressor model data should be consulted to obtain correct cooling water pipe
size. Pipe sizes are determined by cooling water inlet temperatures and specific
compressor heat load. A standard design is based on 95°F (35°C), 60% RH, inlet air, 80°F
(27°C) cooling water with a 25°F (13.8°C) temperature rise in the cooling water. Higher
water flows are required to remove the same amount of heat at higher inlet temperatures.
When cooling water is discharged to an open, drain the discharge lines should be looped
above the highest cooler to insure the coolers remain full of water and do not accumulate
air or other gas pockets.
Condensate drains
Air entering the unit’s first stage carries with it a certain amount of water vapor. The amount
of water vapor that a unit volume of air can hold depends on its' temperature.
Relative humidity is the ratio of the weight of vapor actually present in the air and the
weight that would be present at the saturation temperature and pressure of the air. Dew
point is defined as the temperature at which water vapor in air changes from vapor to
liquid. Condensation is the term given to the vapor-to-liquid change of state.
The amount of condensation (water) produced in the compressor can be considerable.
3 3
Compressing 1000 ft (28.32 m ) of air that is at 90°F (32°C) with 70% relative humidity to
100 PSIG (690 kPa) will result in approximately 4.5 gallons (17 liters) of water being
produced each hour.
A free-flowing means to remove this water from the compressor is required. Each
compressor is fitted with a condensate drain system for water removal. Each stage will
have one or more drain traps piped from the compressor moisture separator area. The
most common type of condensate drain trap is illustrated in Figure 12.
The customer-installed drain lines from the trap and/or the bypass line should be
positioned so that the condensate drainage is visible. This provides the operator with a way
to check that the trap is working.
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Compressor stage (Typ)
Trap vent
Float Condensate drain
Valve
Trap bypass valve

Air gap
Drain trough
To floor drain
Figure 12
Standard condensate trap and drain arrangement
The traps drain line termination should not reach below the water level in the trough or
floor drain. On compressor unload or start, drawing of a vacuum is possible. Condensate
could be drawn up from the drain in the reverse direction through the trap and into the
compressor in the vacuum situation. Additionally, the traps drain line termination should be
at a height lower than the bottom of the drain trap to insure complete trap drainage. The
condensate will normally be blown out under stage pressure.
If the unit is to be left unattended or in a location where maintenance may be minimal, a
high level condensate alarm or shut down feature is available as an option to the control
system. See Figure 13.
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Trap vent
Condensate
drain
Magnetic switch
Alarm level
Float
Figure 13
Condensate level alarm arrangement
High condensate alarms are electrically wired in series with one another and any stage that
has a trap that is not working will alarm or shut down the machine. The series connection
makes float-switch troubleshooting difficult since one faulty switch affects the entire circuit.
Instrument air
Instrument air must be provided for the pneumatic control valves and for the seal air
requirements. Instrument quality air only should be supplied. In general terms, instrument
quality air is defined as clean, dry, oil free air. Regulators are provided in the control panel
or on the valves to reduce instrument air to working air pressures. Regulated instrument
air must not exceed the downstream component maximum pressures.
The piping from the instrument air source should be constructed of 1/2 inch (1.27 mm)
minimum non corroding material to limit the possibility of corrosion products entering the
system.
A final stage absolute filter just before the instrument air pipe control panel connection (IA)
is recommended. This filter should be capable of filtering to 5 microns.
If the instrument air system will not be available until after compressor startup, an auxiliary
IA system will be needed. Figure 14 illustrates a method to use bottled N2 for startup and
emergency back up. An auxiliary small compressor with proper filtration could be used for
the same purpose.
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Normal IA supply
To IA
NITROGEN 5 micron
Figure 14
Temporary instrument air supply
Compressor lubrication
Prior to aligning the driver to the compressor (if required), it will be necessary to have the
various lubricants and cooling water required by the Centac compressor in the machine.
Lubricants are normally provided by the customer. Lubricants required are coupling
grease, the compressor lubricant and the driver lubricant.
If the driver is a sleeved bearing electric motor or steam turbine, the lubricant used for the
Centac compressor is normally used for the driver. Drivers with anti-friction (ball or roller
type) bearings use greases recommended by the driver manufacturer.
Lubricants used in a Centac compressor are specified by physical composition rather than
brand or trade name. Physical composition specifications are required because there have
been numerous instances where a lubricant supplier changes oil composition without
changing the product name. This wrong composition oil was then used in a Centac
compressor with problematic results. The chief problem encountered with these wrong
composition oils is heavy oil build up on the bearings causing premature bearing failure.
Always obtain turbine quality lubricant that has been specified by physical composition
rather than trade name. Do not use hydraulic fluids that may have a specification similar to
the Centac compressor specification.
The specification for turbine grade oil for all models other than 0CV, Engine Drive units,
and frame 6 lubricant is as follows:
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Property ASTM Test Method Limits

PHYSICAL:
ISO Viscosity Grade D2422 32
Viscosity at 40 C, cST D445 28.8-35.2
Viscosity Index, min. D2270 100
Pour point, C, max. D97 5
Flash Point, C, min. D92 200
CHEMICAL: (a)
Total acid number, mg KOH/g, max. D664 or D974 0.1
PERFORMANCE:
Oxidation stability
TOST, Hours to neut. No. 2.0, min. D943 7000
RBOT, Minutes to 175 kPa drop, min. D2272 1000
Emulsion, minutes at 54 C to drop to 3 D1401 20
mL, max.
Foaming, Sequence 1, D892 30/0
tendency/stability, mL, max.
Rust prevention characteristics D665B Pass
Copper corrosion, 3 h at 100 C, max. D130 1
Sludge and corrosion control, mg D4310 50
CLEANLINESS:
Particle count (b) ISO 4406 16/13
Water Karl Fisher 100 ppm
a. The premium mineral base oil used to formulate the lubricant covered under this
specification shall satisfy the requirements of Group II Specifications. While presence of
oxidation, corrosion, foam and metal deactivator additives is permitted, only minor quantities
of other additives may be used as required for satisfactory performance in turbo
compressors. Additives must contain no more than trace of sulfur, zinc, calcium, barium or
other metallic elements which may lead to deposits, varnish, or corrosion under high
temperature and stress conditions at bearings and seals. No sulfur or sulfur-phosphorus
anti-wear or extreme-pressure additives are to be used.
b. Since lubricant manufacturers do not usually guarantee cleanliness levels of finished
products, the lubricant should be filtered to this level as it is added to the compressor.
c. Value as produced. Recommended storage is indoors to prevent water contamination.
NOTE
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Failure to meet this specification may result in damage to internal compressor

components.
NOTE
This specification does not apply to X-FLOs, 0CV, or engine drive units.
NOTE
The Pour point specification must be met unless there is a means available for
heating the oil when used in low temperature areas.
NOTE
Oil specifications are constantly being reviewed. Verify that correct oil is used by
consulting appropriate serial number manual. Ingersoll-Rand does not endorse any
other trade name product or any individual oil company.
WARNING
Do not attempt to run the Centac compressor if it has a greased type coupling
that has not been checked for lubrication. Coupling failure and possibly damage to
the driver or compressor will result.
Model 0CV uses 0CV Fluid (I-R Part 1X15023 for 5 gallon pail or 1X11101 for 55 gallon
drum). Lubricants for X-FloÒ and Centac compressor Frame 6 must adhere to the
specifications established for these machines as listed in their respective instruction
manuals.
Some oil mixtures are incompatible with each other, and form varnishes, shellacs, or
lacquers which may be insoluble. These deposits can cause serious trouble such as
clogging the oil filter. Oils of different manufacture, name or specification should not be
mixed.
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Coupling greases
Consult the machine Operators Manual for specific grease recommendation. Several
greases are commercially available for coupling use. Only the highest quality coupling
greases should be used. The two greatest causes of coupling failure are mis-alignment and
faulty lubricant.
Couplings must be disassembled and hand packed with grease to insure full
coupling gear coverage. Using zerk fittings and a grease gun with the coupling bolted
together can result in insufficient grease being applied.
Electrical connections
0CV and 1CV have flanged motors and normally contain the motor starter as an integral
part of the control system. The electrical installation requirement for the integral starter
configuration is to simply provide the main power source to the control panel. All other
electrical cabling is connected inside the control panel by the factory. On those units that
have remote starters or optional electrical accessories a number of external electrical
connections are required. Figure 15 illustrates the electrical connections normally required.
On Model 0CV a reduced voltage starter must be used. The reduced voltage starter in the
case of 0CV is for protection of the compressor. Models other than 0CV may have across
the line starters.
Remote switch gear

Inlet filter differential
pressure switch
kw pf
volts amps
Control power
CENTAC
Ingersoll Rand
Driver power
Current transformer
Water flow switch
CR1 dry contacts
Other remote sensorsor
controls (CEM) Starter Ma contacts
Figure 15
Remote starter and other connections required
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For safety and other reasons, the main power connection must be made by
customer electrical-trade qualified personnel.
The control power inside the control panel will normally supply the pre-lube pump and
electric demister as well as the compressor controller.
In 0CV and CV units with integral wye delta starter the factory pre-wires the CT in the
control panel. This CT is connected in a motor winding phase and senses motor phase
amperage. The microcontroller in this case is programmed with a feature that multiplies the
motor phase amperage by 1.73. This multiplying feature provides the motor line amperage
value that the microcontroller needs for its control functions.
WARNING
The secondary of an energized current transformer (CT1 & CT2) must never
become an open circuit. The secondary must remain shorted. Under open circuit
conditions a hazardous potential (voltage) is developed in a CT secondary when the
primary has current flow.
The microcontroller required current transformer, in remote starter units, could be located
in the remote switch gear, in the motor connection box on the motor or in some other
location before or after the starter. Location depends on the installation plans for the
specific unit. Wherever the current transformer is physically located, it must sense only
one line phase and monitor motor line amperage alone. In installations where the line
leads are made up of several actual cables all cables in the sensed phase must pass
through the CT. See Figure 16.
WARNING
The L1-L2, L2-L3, L3-L1 phase voltages must be within 2% of the line voltage.
A phase imbalance of greater than 2% indicates a potentially serious problem.
Operation of the driver motor with a phase imbalance greater than 2% may result in
motor damage. An improperly wound or connected motor can cause a phase
imbalance. Test for phase imbalance before and during initial run of driver. The
cause of the phase imbalance must be determined and corrected.
WARNING
All models of 0CV must have a reduced voltage starter. Attempts to start a
model 0CV with an across the line starter will result in severe damage to the
compressor.
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L1 L2 L3 T1 T2 T3
L1 L2 L3 L1 L2 L3
CT
CT
T3 T3
A CT installed in a line lead on A CT installed after the starter in

any type remote starter is correct. a motor phase line is correct only
on an across the line type starter.
Figure 16
Current transformer placement
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Table 1
MINIMUM PIPE SIZES *
Model Air inlet Air discharge Air bypass IA and CA
0CV 6 in (152.4 mm) 2 in (50.8 mm) 1.5 in (38.1 mm) 1/2 in (12.7 mm)
C10- C14 8 in (203.2 mm) 3 in (76.2 mm) 2 in (50.8 mm)
C16-C18 10 in (254 mm)
C21-C30 12 in (304.8 mm) 4 in (101.6 mm) 3 in (76.2 mm)
C30-C40 14 in (355.6 mm) 6 in (152.4 mm) 4 in (101.6 mm)
C40-C55 16 in (406.4 mm)
C55-C90 20 in (508 mm)
C90-C110 24 in (609.6 mm) 8 in (203.2 mm) 6 in (152.4 mm)
C125-C150 30 in (762 mm)
C150-C300 36 in (914.4mm) 12 in (304.8 mm) 8 in (203.2 mm)
Note: Do not use these numbers to size customer pipe. The above sizes are for general
informational use only. Consult specific compressor data sheets for specific installations.
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Installation check list

This listing is for general information. The Centac compressor Installation Planning Checklist
provided in other documents is to be used as the formal checklist in the pre-Installation
meeting.
A. Arrival inspection
Shipping damages (list any) ..................................................................................... ¨
B. Foundation
1. Anchor bolts (installed) ..................................................................................... ¨
2. Access to drain (available)) ................................................................................. ¨
.
........................................................................................ ¨
C. Level of machine
(satisfactory)
Grout (if required) .................................................................................................... ¨
D. Piping general
1. Hangers and supports ......................................................................................... ¨
2. Correctly sized .................................................................................................. ¨
3. Proper material .................................................................................................. ¨
4. Expansion joints (when used)
(a) Properly anchored ................................................................................... ¨

(b) Shipping restraints ................................................................................. ¨
5. Flanged for maintenance and inspection ................................................................ ¨
.
6. Drip legs in horizontal run low points ..................................................................... ¨
E. Inlet pipe
1. Non-rusting material ............................................................................................ ¨
2. Long radius elbows ............................................................................................. ¨
3. Pipe size reduction gradual transition .................................................................... ¨
4. Increases one size every thirty feet of ....................................................................... ¨
total length
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5. Filter
(a) Not in air stream flow from plant exhausts, water ................................................ ¨
towers other inlet contaminants .
(b) Delta P gauge ........................................................................................ ¨
6. Provision made for pre start cleanliness inspection of ................................................ ¨
pipe and filter .
7. All general pipe requirements met ........................................................................ ¨
8. Temperature and pressure gauges (if provided) ..................................................... ¨
F. Bypass pipe
1. Silencer properly installed (If provided) ................................................................ ¨
.
(a) Drip leg added if installed in the horizontal position ................................................. ¨
2. Discharge protected from ingestion of rain, snow other ................................................ ¨
contaminants .
3. Directed so that foreign matter will not be blown into ................................................ ¨
inlet filter .
4. Long radius elbows ............................................................................................. ¨
G. Discharge pipe
.
2. Long radius elbow .............................................................................................. ¨
.
3. Block valve ....................................................................................................... ¨
4. Temperature and pressure gauges (if provided) ..................................................... ¨
5. Control air connection (see check list paragraph 7) ................................................ ¨
.
H. Condensate drain
1. Provision for operator to view discharge ................................................................ ¨
2. Termination above top of water level ..................................................................... ¨
I. Cooling water
1. Air cooler high point vent with flow indication .......................................................... ¨
CST-TP0006
2. Flow switch properly installed .............................................................................. ¨

3. Backflush properly installed (if provided) ............................................................... ¨
.
4. Stop valves ..................................................................................................... ¨
5. Throttle valve on discharge (if provided) ............................................................ ¨
.
6. Pressure and temperature gauges (if provided) ....................................................... ¨
.
7. Strainer (if provided) ............................................................................................ ¨
8. All general pipe requirements met ...................................................................... ¨
.
J. Control Air
1. Penetration into discharge pipe at a minimum of 10 ................................................ ¨
pipe diameters from discharge check valve .
2. Non-rusting material ........................................................................................... ¨
3. Minimum pipe size ............................................................................................. ¨
4. Shut-off valve ..................................................................................................... ¨
.
5. Drain fitting ....................................................................................................... ¨
K. Instrument air
1. Clean, dry, oil free air supplied ........................................................................... ¨
2. From downstream side of dryer ........................................................................... ¨
3. Provision for startup with no plant air available ........................................................ ¨
.
4. Filter installed ................................................................................................... ¨
L. Electrical
1. 0CV reduced voltage starter installed (mandatory) ............................................…. ¨
2. CT correctly installed .......................................................................................... ¨
3. Starter pre-programmed (normally is customer ....................................................... ¨
responsibility) .
4. Control power provided ....................................................................................... ¨
5. Remote devices wired
(a) RTD ...................................................................................................... ¨
CST-TP0006
(b) Inlet filter delta-P ................................................................................... ¨

.
(c) Flow switch .......................................................................................... ¨
(d) Others (see P & ID Diagram) .................................................................... ¨
6. CEM wired computer to compressor .................................................................... ¨
.
(a) Other electronic communications wired ...................................................... ¨
7. Driver line voltage within 10% of rated voltage with 2% ................................................... ¨
or less phase voltage imbalance.
M. Other
1. Correct specification Lube oil available .......................................................... ¨
2. Correct specification Coupling and motor ............................................................ ¨
bearing grease available
3. Coupling and motor bearings greased ............................................................ ¨
CST-TP0006

Installation Guide: Centac

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Installation Guide: Centac

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CENTACÒ

Ó 1992, 1999 Ingersoll-Rand Company

Copyright Ingersoll-Rand Company 1997

Transporting the Centac Compressor

Prior to Centac compressor arrival

Centac compressor arrival at the customer site

Failure to observe these precautions can result in severe injury or death.

Storing the Centac Compressor

Up to 180 days' storage under controlled environment

After 180 days' storage

Storage under adverse conditions

General Specifications for Centac Compressor

The plant layout

0.0005 inches/foot 0.001 inches/foot

Machinist's Level Machinist's Level

CV0 is leveled from the discharge flange

Adjusting compressor package for level

Leveling wedges Leveling shims

The inlet piping

Max p 0.3 psig (2.1 kPa)

Inlet air temp Removable

Long radius elbow

The bypass piping

Alt. side wall discharge

The discharge piping

CA tap in. To be located

Discharge pressure Non-rusting control air line.

Long radius elbow

The control air piping

It is important that expansion joint installers consult the manufacturer's installation

Expansion joint bellows Retaining rod

Parallel operation with reciprocating compressors

CENTAC ON LINE WITH RECIPROCATING COMPRESSORS

Langelier's Index is a technique of predicting whether water will tend to dissolve or

O P TIONA L C OOL ING W A TE R S YS TE M B A CK FL US H

Flow ind ica to r

Tem per ature

Thro ttle v alv es

* V alv es and g aug es n or ma lly s upp lie d by cu stom er

INCORRECT ATTACHMENT CORRECT ATTACHMENT

Paddle hits pipe

Compressor stage (Typ)

Float Condensate drain

Trap bypass valve

Property ASTM Test Method Limits

Failure to meet this specification may result in damage to internal compressor

Remote switch gear

A CT installed in a line lead on A CT installed after the starter in

Installation check list

(a) Properly anchored ................................................................................... ¨

2. Flow switch properly installed .............................................................................. ¨

(a) RTD ...................................................................................................... ¨

(b) Inlet filter delta-P ................................................................................... ¨

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