OPERATING PROCEDURE

SERVICE AND INSTRUMENT

COMPRESSED A I R SYSTEM
 Opet-a"L (111s pei-sanne1 siiou 1ci hecome t i.~~i-oi,igi.~ 1y
,Farnmiliat- t r i t i ~ t i l e system to be p i a c e d r i i i
.
sef-vi ce The m a r i ~ ~ ~ F a t-s c t ~mariual
~re s a.i-td oi~er-at
i ng
pi-ocedur s s , p e r t a - in-i11g t o t h e ec1~1.i
pmentj ~ stem
y ,
sh0~11d be read i n i t s errki I-ety and F i i l l l y
undet-stood b e f o r e proceed.irig t.;~,it t i ti.)@ ~,lpe~-at--iar~
o T' t f i e s c l .i .
~pment
~

TI1is ope t-at ing procedure -i' s izr t - i t t e n I tile

assumpt ian t h a t t h e s y ~ t e r n / ~ !-icpi~~~ e i l i i-12s
; b~?~i?
commi ssioiled and inri t i a l operatzions comj~!~t~!ci.
Ttiei-efot-e t h is pi-ocedure w i 1 1 I"@ P 1ect 011 7 y ?:i~@
'I day t o day s t a r t - u p and sii~~.tclswn uperat=ian ~7r
t h e systein/equ ipment .
"NOTE " A1t e r n a t e corr~p
I-essor operat xi
ans
weekly i n o r d e r t o i n s u r e equal
o p e r a t i n g time, t o prove equipment
r e 1 i a b i 1it y and prevent damage t o
non-operating equipment.

"WARNING" Before maintenance can be perform on

system o r equ ipment insure t h a t a7 7
e l e c t r i c a l c i r c u i t s ar-e deenergized,
p i p i n g systems a r e depressur-ized and
t h e proper s a f e t y p e r m i t s a r e a p p l i e d
a t a l l i s o l a t i n g points.
 TABLE OF CONTENTS

General
Function
System D e s c r i p t i o n
Drawi ngs
Prerequisites
S t a r t - u p Compressor
Main Compressor
A i r Dryer
Normal S t a r t - u p
Valve Line-up
P r e - s t a r t Checks
S t a r t - u p Compressot-
Main Compressor
A i r Dryer
Operations
S t a r t - u p Compressor
M a i n Cornpressor
A i r Uryer
O p e r a t i o n a l Checks
S t a r t - u p Conlpressor
~ an iCompressor
A i r Dryer
A i r Receiver
P i p i n g System
A l a r m Response
t4ai n Co~ripressor
A i r Dryer
'I.roubl e S h o o t i ng
A t t a c h m e n t 1 - S t a r t - u p (;cmpressor
A t t a c h m e n t 2 - Main Conlpressor
Attachment 3 - A i r Uryer
O p e r a t i n g and Per-formance D a t a
 --
GENERAL

Function

I tie f u n c t i oti o f - t h e C:otnpr.essed A i I- s t i is t l ~

p r o v i d e set-v i c e a.i r f o r - g e n e r a l Durpose r.~se i t - ) ttre

b o i l e r and t u r b i n e a r e a s , p iiI - a r - e a , c::W
pump h o u s e , coa 1 hand 1 -irig a r e a , rrrai nterianc;e shops
and t o .the f l y a s h t . r a n s p o r . t syst.ern. 1'tie syst.eni
also provides a clean, dt-y SOI..JI-C:F? o f i t to
in s t r - u l n e n t s arid c o t i t r o l s t,hroitgt-lout .the p l atit; f o r -
morii t o r irig and pr-ocess c o r i t r - 0 1 .

Syst.em D e s c r i p t i o r i

The s e r v i c e atid in s t r u l n n n t a i r s y s t e m c o r ~ ssi t o f

t w o ( 2 ) 3 s t a g e c e n t r i f u g a ; compressor-s h a v i n g a
o u t p u t c a p a c i t y o f 6 7 . 4 5 PJM"/Mili., one ( 1 j 2 s t a g e
c e n t r i f u g a l c o l n p r e s s o r kiz~ving a o u t p u t capac i - t y c-rf
3 5 . 1 0 N M ' / M ~ n . , one ( 1 ) s t , a r t - u p c o m p r e s s o r , t w o ( 2 j
100% r e f r i g e r a n t t y p e a i r d r y e r s , t w o (21 a f t e r
f i l t e r s , one ( Ij s e r v i c e air r e c e i v e r , one ( 1 i
ir~strurnerit a i r receiver, p iping, v a l v i ng arid
i n s t r c r m e n t a t i o t - i arid coti-t.1-01s f o r motii t o r i n g atid
c o n t r o l 1 i rig t h e p r o c e s s .

Each cetit,r-i f u g a l corlipt-essor- i s nlounted ( ? t i a s k i d

arid contains the coml.)I.essor, a it i t e r c o o l e r ,
a f t e r . c o o l e r , l u b e o i l r e s e r v o i r , rnaiti l u b e o i ' i
pump, p t - e - l u b e o i l pump, i t i l e t f i l t e r - , i t . 1 1 e t atid
b y p a s s c o r i t r o l v a l v e and c o n t r o l s y s t e m .

The c o n t r o l s y s t e m ir i c l crdes a1 1 t j e v i c e s n e c e s s a r y
for starting and s t o p \ _ i, ng the compressor,
c o n t r o l 1 ing s y s t e m p t - e s s u r e , atid a s s u r irig saTe
operatioti w i t h respect t o lubricatiori, v i bratioti
and t e m p e r a t u r e . The hasic control sys.tem is
d e s i g n e d f o r c o n s t a n t , p r e s s u r e o p e r a t i oti . ..,.j. -
' I L

The c o n t r o l s y s t e m a l s o i n c l u d e d a s u r g e s e n s i n g
d e v i c e w h i c h p r o ' L e c t s t t i e c o n i p r e s r o r f roni s u s t a i tied
o p e r a t i o n i n t h e crnstable surge r e g i o n . If t h e
surge , Ze-n~o~r detects compressor surge, it
a u t o n i a t i c a l l y u n l o a d s tt.re unit,.

The coriipressor is operal:.ed by t w o rne-thods , rnodu 1 a t e

c o n t r o l and a u t o - t l u a l cc~n1;rol .

Modul at.e .type o f c o n . t r o 1 mai t i t a i 11s t,he s y s tern

p r e s s u r e a t a c o n s t a n t v a l u e , w h i c h i s accompi islied
by t h r o t t l i t i g t h e i n l e t ; v a l v e \git;hiti t h e con,-
.. p r e s s o r ' s t h r o t t l e range.
ilam
 I f systern f 1 ow demarid i s 1 e s s t h a n t h e m.i t i irnr~rrl
t h r o t t l e d c a p a c i t y , cor1st;ant d i s c h a r g e p r e s s u r e i s
m a i n t a i ned by l e a v i r i g t.he t h r ~ o t . t l e din'1e.t va 1 ve at,
t h e m i nimum t h r o t t l e d c a p a c i t y arid t h r o t t i irig I;he
bypass v a l v e . T h r o t t l i t i g 1,he b y p a s s v a l v e p r o v i d e s
capacity con-trol from the miniriium tk1roLtled
c a p a c i t y t o z e r o c a p a c i t y r e q u i I-enietits .

When t h e colripressor is oper-aterl un ioaded , t h e

bypass v a l v e i s f u l l y opet, and t h e i ~ i . l e tv a l v e i s
held partiall y open by a signal -from t11e
c o r i t r o l l e r . I h e smal 1 arnount o f a i r -t.ha-t passes
t h r o u g h t h e cornpressor b r l l i l e i n t h e crri'loacl [node,
r e c i r c u l a t e s t o t h e i n l e t t h o u g h Lhe bypass v a l v e .

The compressor i s a t .fu'l 1 c a p a c i t,y wtietl t h e . i n l e t ,

v a l v e i s f u l l y open arid .the bypass v a l v e i s f u l l y
closed.

As f 1 ow demand decreases, cons.tant d isct.1arge

pressure i s maintained by reduc i n y the f iow
delivery t o t h e s y s t e m by t h r o t t l i n g t h e inlet,
v a l v e and k e e p i n g t h e bypass v a l v e . f c r l l y c l o s e d .

As f 1ow d e l iv e r y is r e d u c e d and t h e maxi mum in 1 e ' t

throttle range i s reached, the co~npr.e.ssor
a p p r o a c h e s i t s s u r g e p o i n t . Any f u r t h e r r e d a c t i o n
i n c o m p r e s s o r c a p a c i t y w o u l d cause t h e u n i t t o
become u n s t a b l e and o p e r - a t e w i t t i . i r 1 t h i s s u r g p
r e g i o n . To p r e v e n t t h e cornpr-essor f ronl ope r a t irlg
w i t h i n t h i s r e g i o n , t h e i t i l e t v a l v e i s h e l d open by
t h e c o n t r o l s i g n a l a . t t h e rnaximunl i n l e t t h t - o t t . l e
point.

As systern f l o w r e q i l i rernents c o n t i nue t o d e c r e a s e

below t h e i n l e t t h r o t t l e range o f t h e compressor,
t h e compressor w i l l continue t o follow these
demands by b l o w i n g o f f SUI.-plus a i r L h r o u g t i t h e
bypass v a l v e .

AUTO-DUAL CONTROL

A u t o - d u a l c o n t r o l f u r i c - t i o n s t h e same a s rnotlu l a t e
c o n t r o l , b u t has an add i l;.i o n a l "Modu 1 ate+'rwo.-St1.p"
control mode. Selection between rnodcr1at.e and
m o d u l a t e + t w o - s t e p c a n be rnade a t t h e c o n t r o l p a n e l .
When c a p a c i t y r e q u i retnerits a r e w i t,hi 1.1 .the t h r o t t l e
r a n g e o f t h e cornpressot-, t h e corrlpressor o p e r a t e s
e f f i c i e r r t l y by autornat, i c a l 1y t h r o t t l i n g t h e i n l e t .
v a l ve t o mai n t a i n const,an't p r e s s u r e . I f capac it.y
reqir ir e m e n t s d e c r e a s e be 1 ow t h e rrlax irnr-cni t h r . o t t 1 e
r a n g e , t h e cornpressor- w i 1 1 crnl oad. When s y s t e m
p r e s s u r e decreases t o a p r e s e t c u t - i n p r e s s u r e , t h e
c o m p r e s s o r w i l l go t o f u l l l o a d .
The compressor w i 11 iricrease d is c h a r g e pr.essut-e t o
t h e c o n s t a n t p r e s s u r e s e t t i rig, and w i 1 1 respond t,o
t h e demarid reqir i renierits o f .the systerri b y remai n in g
a t f u l 1 l o a d o r t h t - o t t l 'iriy and t h e n ~ c l - i l o a d i t i y .

A i r f l o w s f r o m atmosphere throcryh t h e i n l e t f i l t e r -
t o t h e f i r s t s t a g e o f t.he conlpr-essor. The a i r f l o w
,t.o t h e cornpressor i s c o n t r o l l e d by t h e i ti'let,
c o n t r o l v a l v e . The a i r i s C O I ~ ~ I - e s s ei 1 d
1 the f i r s t
s t a g e and i s d i s c h a r g e d tl.irough t h e - F i r s t s t a g e
in t e r c o o l e r where t l i e mo is'tut-e c o n t a i ned it i tl-ie a.i 1.-
i s condensed and t h e condetisate i s discharged h y
t h e automat ic d r a i n va.1 ve t o w a s t e . 'The compr-.essed
a i r t h e n e n t e r s t h e second s t a g e o f t h e compressor,
t o be cornpr.esssd to : l.iighet.' p r - e s s ~ ~ r . eand , is
d is c h a r y e d t h r o u g h t h e secotid s t a g e in t e r c o o l el-
where the rnoistt.rre c o n t a i n e d in the air is
condensed atid t h e c o r ~ d e n s a t ei s d -ischar-ged by t.hs
a u t o m a t i c d r a i n v a l v e t o was.te. -1 t.ie a i r t h e n e n t e r s
the t h i r d stage o f t.he conlpr-essor wliere it. i s
compressed to the tlesit-ed pressure arid is
discharged through the a f t e r - c o o l er. where t t i ~
moisture in the air is condensed and t:,l,ie
condensate is d iscPia.r.gec-1 b y t h e aut01nat.i c d r a i t i
v a l v e t o waste. The a i r - t h e n f l o w s t o t h e s e r v i c e
a i r r e c e i v e r . The system p r e s s u r e i s m a i n t a i n e d
c o n s t a n t by m o d u l a t i n g t-he i n l e t c o n t r o l v a l v e and
t h e bypass c o n t r o l v a l v e .

The s e r v i c e a i r r e c e i v e r s u p p l i e s a i r t.o t h e p l a n t
a r e a s f o r g e n e r a l u s e , t,o t h e f l y ash t r - a n s p o t t
system and s u p p l i e s a i r t o t h e iristr-t~ment. a i r
d r y e r s . A . i r e n t e r s t h e a i I- dryer- r.rhere any m o i s t ~ r r e
c o n t a i n e d i n t h e a i r .is coridensed and r-ernoved by
t h e a u t o m a t i c d r a i n v a l v e s where i t i s d i s c h a r g e d
t o waste.

The d r y a i r f l o w s t o .the instrument a . i r r e c e i v e r .

From t h e r e c e i v e r a i r i s s u p p l i e d t,o t h e plat1.t
a r e a s w h i c h r e q u i r e d r y a i r f o r contr-01 1 i n g t h e
p l a n t process.

I n .the e v e n t t h a t low system a i r p r e s s u r e shot.11d

o c c u r a motor 0peratet.1 v a l v e l o c a t e d i n t h e s u p p l y , ,.. ' ,
t o t h e p l a n t general s e r v i c e closes. A furt.her
r e d u c t i o r i i n a i r p r e s s u r e c l o s e s a rno'tor o p e r a t e d
v a l v e i n t h e s u p p l y t,o t h e f ' l y ash t r . a r i s p o r t
system.

The f l y ash t r a n s p o r t system can be s u p p l i e d from

both u n i t s .
DRAWINGS

S t a r t - u p Compressor

380 V Power a v a i l a b l e .

Mai n Conipressor

C l o s e d c o o l i n g w a t e r system i n s e r v i c e .
3 8 0 V Power a v a i l a b l e .
C o n t r o l Power O n .
Compressor s e a l a i r a v a i l a b l e .

A i r Dryer

38u V Power a v a i l a b l e .
C o n t r o l Power O n .
380 V Power u n a t 1eas.t 4 t7our.s b e f o r e p l a c i n g a i r
dryer i n service.

NURMAL START-UP

V a l v e L i ne-up

As p e r P & l D 1 s 2 - 4 6 - F C 0 7 - 7 3 3 1 - 0 7 1 - 0 1 - 0 4
2-46-FCIJ7-7331-071-~5

P r e - s t a r t Checks

S t a r t - u p Compressor

Verify o i l l e v e l normal.

Mai n Compressor

V e r i f y c o o l i n g w a t e r on t o t h e cnmpressor.
Check open i n s t r u n l e n t a i r s u p p l y t o c o t ~ t r o l
panel .
V e r i f y seal a i r regulator s e t t o maintain a
minimum o f 6 PSPG s e a l a i r p r e s s u r e .
V e r i f y t h a t p r e l u b e pump s t a r - t s when c o t i t r o l
power t u r n e d o n .
V e r i f y lube o i l p r e s s u r e normal (appro.*:. 2 0
PSIG).
V e r i f y lube o i 1 pressure greater than 6 5 ' F .
V e r i f y i n l e t c o n t r o l v a l v e c l o s e d and bypass
c o n t r o l v a l v e open.
V e r i f y d i s c h a r g e p r e s s u r e a d j u s t e d t o d e s i r e d set.
point.
 V e r i f y on C R T i n cont.r.ol roorn compressor ready
indication.

A i r Dryer

V e r i f y Power On a t l e a s t 4 h o u r s .
Check compressor c o o l i n y c o i 1s c l e a n .
V e r i f y condensate d r a i r l t r a p s f u n c t i o n a l .

O p e r a t ions

Start-up Compressor ( S t a r t )

Close r e c e i v e r o u t l e t valve.
S t a r t compressor.
Y e r i f y compressor l o a d s and r e c e i v e r p r e s s u r e
increases.
V e r i f y compressor shutdown whet1 p r e s s u r e s e t p o i nl;
i s reached.
* Place s t a r t - u p d r y e r i n operation.
S l o w l y open r e c e i v e r o u t l e t v a l v e .
V e r i f y compressor l o a d s .

" N o t e " 1-he s t a r t - u p cornpressor s y s t e m i s desigriec-l

o n l y . t o s u p p l y a i r t,o main cornpr-essor s e a l s
and t o c o r i t r o l c a b i n e t when no o.t;her s o u r c e
of a i r i s available.

S t a r t - u p Compressor (Shu t;down)

Close r e c e i v e r o u t l e t valve.
S t o p compressor.
Rernove s t a r t - u p a i r d r y e r f r o m s e r v i c e .

Main Compressor

Local S t a r t - u p

From l o c a l c o n t r o l parlel p l a c e s w i t . c l i t o l o c a l
position.
P l a c e mode s e l e c t o r - s w i t c h t o u n l o a d p o s i t i o t l .
V e r i f y compressor r e a d y s i g n a l i n d i c a t e d .
V e r i f y emergency s t o p pr.~shb u t t o n reset,.
A t l o c a l c o n t r o l p a n e l p r e s s s t a r ' t push b u t t o n .
V e r i f y p r e l u b e o i l purnp s t o p s .
P l a c e rnode s e l e c t o r s w i t c h t o rnodulate p o s i t i o n .
P e r f o r m o p e r a t i o n a l checks.

" N o t e " Compressor w i 11 run c o n t i riuousl y and

pressure setpoint, w i l l be rnaintairled
c o n s t a n t by c o o r d i n a t e d c o n t r o l of the
compressor i n l e t and bypass c o n t r o l v a l v e s .
4.3.2.2 Loca 1 Sliutdowti

P l ace mode se 1 ec-Lor- sw.it.ch t,o u n l o a d p0s.it.-ion.

Ver if y compressor uri 1oaded .
P r e s s s t o p push b u t t o t i .
V e r i f y p r e l u b e o i 1 punip s t a r t s .

4.3.2.3 Rernote S t a r t - u p

From l o c a l c o n t r o l pane1 p e r f o r m t h e f o l 'io\vi r ~ :g

- P l a c e s e l e c t o r s w i t c h t o remote p o s i t i o t l .
- P 1ace mode se 1 ec;t:-or sw i- t c h t,o motlir I st.^
position.
- V e r i f y emergency s t o p push b u t t o n r e s e t .
Frorn c o n t r o l room MCS keyboard perform the
following fur\ctions:
- Select d i s p l a y F%H.
- Select option A.
- Select optioti YF' - verify a1 1 s-tart
permissive s a t i s f i e d .
- V e r i f y compressor ready r i gtial i n d i c a L e d .
- S e l e c t o p t i o r i A , B o r C f o r - cornpressor t o be
started.
- Press S t a r t
- V e r i f y compressor- s t a r t .
- Perform o p e r a t i o n a l checks.
S e l e c t o p t i o n f o r compressor t o be p i a c e d i n
. s t a n d b y arid p l a c e i1.1 au.t;o.

4.3.2.4 Remote Shutdown

From c o n t r o l room t4CS I<eyboard p e r f o r m t h e

following functions:
- Select display F28.
- Select option A.
- S e l e c t o p t i o n fnt- compressor t o be removed
f rorn s e r v i c e .
- Press s t o p .
- V e r i f y compressor s t o p s .
L o c a l 1 y v e r i f y p r e l u b e pump s t a r t s .

4.3.3 A i r Dryer

4.3.3.1 Local Start-up

"Warning" I f t h e m a i n power s c ~ p p l y has heeri

t u r n e d o f f f o r more t h a n 4 hocrrs or-
1onger-, w a r m up t h e craril<case Ilea her
b e f o r e s t a r t i r ~ gt h e d r y e r . F a i l u r e t o
do so w.i 11 r-esul t i n damage t o t h e
d r y e r cornpr-.,.
PC-SOT.

V e r i f y 4 h o u r warmup c o m p l e t e .
Frorri l o c a l c o n t r o l p a n e l p l a c e s e l e c t o r s w i t c h t o
local position.
P l a c e d r y e r o n / o f f s w i t c h t o or) p o s i t i o n .
 V e r i f y by-pass v a l v e c;losed.
P e r f o r m o p e r a t i o n chec;l:s.

4.5.3.2 L o c a l Shutdown

From l o c a l c ; o n t r o l pariel s e l e c t o r s w - i t c l i t.o l o c a l

position.
P l a c e dr-yer o n j o f f s w - i t c h l;o o f f p c ) s i . t i o n .

" N o t e " Do n o t t u r n o f f main power supply unless

r e q u i r e d f o r mai nl;enance.

4.3.3.3 Rernote S t a r t - u p

Frorn l o c a l c o n t r o l pane1 p e r f o r m t.he f o l 1low.i ng

functions :
- P l a c e s e l e c t o r s w i t c h t o remote p o s i t . i o n .
From c o t - ~ t r o l room MCS 1:eyboard perforrn the
following functions:
- Select display F28.
- Select option A.
- S e l e c t o p t i o n U or. E f o r d r y e r t o be p l a c e d
i t 1 service.
- Press s t a r t .
- Verify dryer i n operation.
- Per-form o p e r a t i o n a l c h e c k s .

4.3.3.4 Remote Shutdown

From c o n t r o l room MCS l<eyboard per-for-111 t h e

following functions:
- S e l e c t d i s p l a y F28.
- Select option A.
- S e l e c t o p t i o n f o r - d r y e r t o be removed f r o m
service.
- Press s t o p .
- V e r i f y dryer o u t of service.

" N o t e " Uo n o t t u r n o f f main power supply unless

r e q u i r e d f o r ma,i nLetiance .

OPERATIONAL CHECKS

S t a r t - u p Compressot-

Check o i l l e v e l n o r m a l .
Checlc compressor f o r ~ ~ n l . ~ s u rjoi
a l ses.
D r a i t i condensate f roni r e c e i ver..
V e r i f y compressor l o a d . i n g and u n l o a d i n g at, p r o p e r
set points.

* REPURI- ALL ABNORMAL C'UNL)l I I U N S I M M E I . ) l A I E l - Y .

M a i n Compressor

Each
- s-h-
- i f t -and ..... s,tat-:t_~u!
e-a...c...h
---- .-.-

Check and r e c o r d t h e o i l t e m p e r a t u r e .to t,he

compressor. c a s i n g .
C:tiecic and r e c o r d t h e c o m p r e s s o r o i 1 pt-essirr-e .
Test a l l warning 1ight.r.
Check and record i n t e r - s t a g e atid sys.tem a i r
pressures.
Check and r e c o r d i n t e r s t a g e and d i s c h a r g e a i r
temperatures.
Checlc and r e c o r d t h e i n l e t a i r . t e n \ p e r a t u r - e .
Check and r e c o r d t h e c o o l i r ~ gw a t e r temper-at;ure,
b o t h t o and f r o ~ ncornpressor man i- f o ld .
Check and b l o w dowt-i t.he c o n t j e r i s a t e t r a p s .
Check and record the inle-t air. f i 1t:et.
d i f f e r e n t i a l p r e s s u r - e o r t h e i n l e t manometer
reading.
Checlc a i r c o o l e r v e n t s - f o r c o n t i n u o u s f l o w . Vent.
v a l v e s a r e l o c a t e d or1 t o p o f t h e c a s i n g .
Drain the condensa.t,e frorri the inlet air,
d i s c h a r g e a i r , and b y p a s s a i r p i p i n g d r i p l e g s .
Check t h e c o m p r e s s o r r - e s e r v o i r o i l l e v e l .
Ctieclc f o r o i 1 1eal:s.
Ctieck f o r w a t e r l e a k s .
checlc t t i e c o n ' t r o l l e d a i r 1 in e and instr-urnen t a.i r
1 i n e f i l t e r s . D r a i n a n y m o i s t i t r e w h i c h may have
c o l l e c t e d and r e p l a c e t h e -F.i 1t e r - e l e r l ~ e n t i f
necessary.
Check s t a n d b y contpt-essor r e a d y f o r s e r v i c e .

* REPORT ALL ABNORMAL CUNL.lI1-1UNS IMMEUIAIELY.

A i r Dryer

Check a l l a u t o m a t i c d t - a i n v a l v e s f o r proper
operation.
Check c o m p r e s s o r o i 1 l e v e l .Normal l e v e l i s m i d
s i g h t glass.
*' Checlc ALL i n d i c a t o r - 1 i g h t s f o r proper- o p e r a t i o n .
Check i n l e t and o u t l e t a i r t e m p e r a t u r e s .
Checlc ir1termediat.e a i r - t e n i p e r a t i . r r e .
Check r e f r.igerarit sirction and d i schar.gs
temperatures.
Check s i g h t p o r t i n t.he l i q u i d r e f r i g e r a n t l i n e
f o r c l e a r o r bubbles, c o l o r y e l l o w o r green.
Check c l e a n l i n e s s o f c o o l i n g c o i l .

* REPORT ALL ABNORMAL CUNIIITIUNS IMMEUIAI'ELY.

A i r Receivers

Check automatic drain valves for proper

o p e r a t io n .
 Check r e c e i v e r s f o r l e a l i s a t mariwnys and t - e i i e f
valves.

P i p i n g System

Check systern f o r p r o p e l - 1 it i e - u p .
- Check s y s t e m f o r l e a k s .
Check systern f o r nioi str.rt-e.

6.0 ALARM RESPONSE

--

6.V. 1 Mai 1.1 Compressor

P -o-
-- ssible C-
a-~ s- e-
~..- -
0 r-r- ..e---c-.ve
.-t-...-..i--
A-c
.-t-. i-o
.. .- n
.-

Low o r n o w a t e r f l o w t o o i 1 c o o ' l e r j E s t a b 1 i s h
c o r r e c t water f l o w .
H.igh s ~ t p pyl w a t e r t e r n p e t - a t u r e j R e d u c e s u p p l y w a t e r
temperature.
I m p r o p e r temperat,ure d e v i c e s e t t , i n g i R e s e ' t tempe-
r a t u r e s e t p o i n t , c a l ib r a t e i ~ i s t r u m e t i t s .
D i r t y o r p l u g g e d o . i l c o o l e r on w a t e r s i d e i l ' l e a n
c o o l e r tubes.

6.0.1.2 Low u i l Pressure

-P
- o s s i b l e Cause/Cor-reccjv,e-- A c t i o n

Improper a d j c ~ s t m e n t o f system p r e s s u r e re1 i e f

v a l v e j A d j u s t system pressure re1 i e f v a l v e t o
c o r r e c t o i 1 pressure.
L e a k i n g o r p.inched o i 1 1 i n e j R e p a i r o r r e p l a c e o i 1
1i n e .
D i r t y o . i l filter/Replac::e o i l f i l t , e r element.
D e f e c t i v e main o i l punir~/Repair o r r e p l a c e main
o i l pump.
Low o i l l e v e l / A d d o i l .

6.0.1.3 H i g h A i r Temperature

P o s s i b l e O a u s e-./ C o r r..--e c t-i -.ve A.- c.-.t i-. o .n

-. - ..-

Low o r tlo a i r f l o w t o a i r . c o o l e r i E s t a b 1 i s h ~ o r -
r e c t a i r f l o w . R e p l a c e f a n mot-or.
u i 9;i S ~ J C Q:J ~ :qaff-r : f - ~ n g o r ~ < ~ r p / F . I ~~1~
. 1lp-ip~
.r' r k~~ ? t , ~ r

-- --
- = v T = , - = -
--., ,-=- .
I n - I D ~ ' J D ~ - rernp per a5l.Jt-q i ~ , ; isc_r~.,?
r,e, ! l q ; ; F c _ ~ c - r?~5 : r r , c -
r a t , ~ j r e s e t , ~ ~ i n t -c.a i i b ~ r : i ~ 2i ~ ~ ~ ~ ~ I J ~ T I ~ I ~ I ~ ~

D i r t y o r plugged a i r coolsrjClearl c o o l i t i g c o i l s .
6.0.1.4 Low Seal A i r Pressur-e

P-o s s i b l e CauseJCorrective
- - --. ..-. .--- .- - .. .. .-. .A
-- ..c t i o...n- .
.. .--

Low instrument a iI- j R e e s t a b i i sh

press1~r.e
instrunlent a i r pressure.
Improper adjustn~ent of seal air pressur-e
regu1 a t o r / A d j u s t regu'Iat;or t o correct, seal a i r
pressure.
Worn s e a l s / R e p l a c e s e a l s .

6 . 0 . I. 5 High V i b r a t i o n

P o s--
- l e CauseJCorrecti
s i b- -.--- --. -- - ----...- ...ve
.. -. . .-..A
-. c
...-t-.i -.
o-.n

Low o i 1 t e m p e r a t u r e / A l low warm-crp p e r i o d f o r o i 1 .

Worn c o u p l i n g j l u b r i c a t e . K e p l a c g c o u p l . i n g .
R o t o r u n b a l atice due t o bu i 1 d-up jCotisu 1 t rnariu-fac-
turer.
R o t o r utlbal ance dcre t o a e r o par.t;s/cot1su 1 t nian\.r-
facturer .
I n d u c e d v i b r a t i o n f rorn d r i v e r . / ~ o n s ut. l dr-iver
manufacturer .
6.U. 1 . 6 Compressor Surge

P o s s i b1 e Cause/Correct;~ye-A-q$jut~

Discharge block v a l v e closedjupen block valve.

I m p r o p e r c a l ib r a t i o r i o f s u r g e serisor/Cal i b r a t e
instrument.
D i r t y i n l e t f.ilter/Change f i l t e r - elenients.
Improper ad j u s t r n e ~ i t , or1 maximurn thr-oLt1~
point/Readjust t o s u i t s i t e conditions.
H i g h i n t e r s t a g e a i r temper.ature/Est;abl i s h c o r r-ect,
water f l o w t o a i r c o o l e r s .
H i g h s u p p l y w a t e r tenipet-atvrejRetjuce s u p p l y w a t e r
tetnperature.
Worn aerodynamic p a r t s / c o n s u l t , m a n u f a c t u t e r .

6.0.1.7 Low u i 1 Temperature

Poss ib l e Cause/Correc.tiv.e---Acti_oy!

a Low s u p p l y water teniperature/Increase scrppl y

water temperature.
Iniproper teniperature d e v i c e s e . t t iriyjKese!; to
correct temperature setpoint. d a i ih r a t e
instrument.
Lube o i l heater n o t f u n c t i o n a l j v e r i f y power
s c ~ p pyl on. Check Lenipet-ature s e t p o i n t c o t r e c t .
Repl ace d e f e c t i v e h e a t i n g element.
'Temperature control valve malf u n c t i o n / V e r i f y
temperature s e t p o i r i t c o r r e c t . Verify c0nt.r-01
v a l v e n o t s t i c l t i ng. Repl ace t e m p e r a t u r e con1;rol
valve.
6.U. 1 . 8 D i r t y 1r)le-t; F i l t e r

Change o u t f i1t e r 9 1~ e r as i r.ecll.1 i r e d . .I f

e x c e s s i v e f i lt e r p l crgy i rig occut-s clet,e~-mi ne cause
and e l i r n i n a t e .

6.U. 1 . Y O i r t y O i 1 F i 1t e r

* change o u t f i 1t e r a1ement.s as req1.r-i r e d . 1-1'

e x c e s s i ve f i lt e r p l u g g i n g o c c u r - s de-Lerrnitie cause
and e l i m i n a t e .
6.U. 1 . 1 U Low C o o l i r i g Water F l o w

P o s s i b l e CauseJCorrec-ti v e A c. t i o~.
n

C o o l i ng w a t e r syst,eni 'lczvljlncrease s y s t e r ~ lf l o w .
l n ' l e t i s o l a t i o n v a l v e c l o s e d ot- - t F ~ r o I ; ted,ic!~)et?
l
i n l e t i s o l a t i o n valve.
O u t l e t i s o l a t i o n v a l v e ' t , l ~ r o t t l e d o r c'losed/i)pen
o ~ t ~ l e i sto l a t i o n v a l v e .
Imr:,r.oper in le t PCV cjev ic e s e . tt i ricjjlieseL 1;r>
.
c o r r - e c t s e t t i n g V e r i f y v a l ve o p e r a t i o t ? . R e p i ar:e
v a l ve.
C;ooling water outlet, s o l e n ~ i d valve n ~ t
w o r k i ngjChecI( v a l v e power. s t r p p l y o n . Kepii3c;e
solenoid valve.

6.U.1.11 Low u i i Level

-- e -c a u s e L. -C
P o s s i b.-l-- o-r-.r.-e
---- - . c- .t...i-v e
. .... A c-
...... .- t i. o.-t-i

System p i p i n g 1 e a k s j H e p a i r . l e a k s . Add o i l .

6.U.1.12 Compressor N o t Ready

- l e CauseJCorrecti-ye...Acct_i_o!j
Possib

Prerequisites not t n e t j E s - t a b 1i s t i r e q e ~ri ~ dp r s -

requisites.

A i r Dryer

I n l e t A i r 'Ternpet-ature H i g h

i b l e Cause/Correcti..v.e--&t;j-oj
P o s s---
-
Compressor a f t e r c o o l e r - ma1 f u n c t i o n i c l l e c i t a f t.er.-
.
c o o l e r d is c h a r g e t e m p e r a t u r e Reduce t,ernper.a.tcrr e
t o 12U°F max.
6.0.2.2 H i g h Evap. L i g h t On

Possi b l e CauseiC'orrec.tive...Act~o~~.

Leak in r e f r igerat,i on systern/Locate 1 e a k , r e p a i r

and r e c h a r g e .
I m p r o p e r a d j ustrnerit o f HGBV j Adj icst Ii!:;BV t o 1 owcl.r.
' s ~ ~ c t i ot enm p e r a . t u r e t.0 c o r r e c t l e v e l .
A i r o r rioncondensahl~~s i n r e f r i g e r a t i o n sys-tern.
P o s s i b l e l e a k i n c h i 1 1 e r i L o c a t e l e a l t s , r-epai I- and
recharge.

6.0.2.3 S u c t ior1 'Temper.at~rr-eH i gh

Poss ib1e C a u s e / C ' o r r e c ~ t i - y . e _ ~ ~ t - : i . ~ ~ ~

Irtiproper a d j u s t r n e n t o f I-IQbVjAdjust HGHV t o lower,

s u c t i o n temperatur-e t o c o r r e c t l e v e l .
I n l e t a i r t e n ~ p e r a t i r r e t.iigher- t;han I : ~ ~ . . ~ " I = / I ~ ~ ~ ( ~ I . . ~ c ~
aftercooler discharge ternperature to dns-i gn
conditions.
Excess i ve a i r .F 1 o w i R e d ~ ~ cae i I- f 1orv.
Leak i n r e f r i g e r a t . i o t . 3 s y s t e m j l o c a t e l e a k , I-epa i r-
arid r e c h a r g e .

6.U.2.4 R e f r i g e r a n t Discharge 'le~npet-at.~H

~ ri e
yh

---- ib l e---Cause/'Cor-r-ec;t
Poss
.. -. -.--- -- ----. .--.---i
..ve
-- -...-.Ac.Li
--..--.-ori
......-

Condenser f ou 1 ed o r c:1 o g g e d j c ' l eat1 or. r-et~ i ~!:e

conderiser- .
Fan rnotor s t o p p e d j f i e s tar-t,. FierYl ace f a l l rr~otot-.
t r~
I n c o r r e c t f a n c y c l in g a d j u s t r n ~ ! r ~ t j ( ~i o r~iantu-.-
s~~
facturer.
Inlet air teniper-at,crr-e t.oo high/Red[.ice air..
t e r n p e r a t u r e t o des ig ~ concji
i t i ons .
"No-tie" A 1 1 a1 a r m c o n d i t . i otis s l ~ o 1ud be acltriow 1 ecjgqtl
and c o r r e c t i v e a c t i o n t a k e n irnmedi a t e 1 y .

TROUBLESHOOTING
-

~ t - t a c h r n e n t1 - S t,ar-t.-.uy! Colnpl-essor .
Attachmerit 2 - Main I:ornpressor.
Attachment 3 - A i r Uryer.
 8.0 qPERATING AND PERFOI€MANCE DATA

CENTAC SPECIFICA"TI0NS

OPERATING D A T A

MODEL: C V 2 29MX3

AIR END

ROTOR ASSEMBLIES
STAGE: IMI'ELLER O.D. IMPELLER EYE VlBRATlON VIBRATION
\ TIP CLEARANCE (Y) CLEARANCE ( 2 ) ALERT SHUTDOWN

VIBRATION MOCIITO~ ALERT (IF PROVIDEDJ AND SHUTDOWN s e ' r r l ~ d sSHOULD BE SET TO THE LEVELS
(MILS) LISTED ABOVE,

AIR COOLERS

M A X I M U M WATER SUPPLY PRESSURE 7 5 PSlG

WATER PRESSURE DROP 1 2 PSI

COOLING WATER TEMPERATURE RISE 25'~

APPROACI-4 TEMPERATURES (C.T.D.)

1 ST STAGE
2ND STAGE
3RD STAGE

REFER T O ELECTRICAL SCHEMATIC FOR AIR TEMPERATURE SWI'TCIi TRIP SETTINGS.

SEAL AlINREQUlREMENTS

SEAL AIR PRESSURE (MAX.) 25 PSlG

REFER T O ELECTnlCAL SCHEMATIC FOR SEAL AIR PRESSURE SWITCIi SETTINGS IIF PROVIDED).
 !

8.0 OPERATING AND P E R F O . R l W A N . C E DATA

QIL SYSTEM

OIL RESERVOIR CAPACITY 6 4 GALLONS

MAXlMiUM QlL COOLER WORKING PRESSUFIE

1 5 0 PSlG

3 0 0 PSlG

OIL PRESSUnE PERMISSIVE START 1 6 PSlG

OIL TEMPERATURE PERMISSIVE START 65'~

P R E L ~ B EPUMP OPERATING PRESSURE 18 PSlG

MAIN OIL PUMP OPERATING PRESSURE 2 0 - 3 0 PSlG

OPERATING OIL TEMPERATURE 105-1 1 5 ' ~

R E ~ E RTO ELECTnlCAL SCHEMATIC FOR OIL TEMPERATURE A N D PIIESSURE SWITCH S E n I N G S .

INSTR~MENT
AIR REQUIREMENT
I
INSTRUMENT AIR PRESSURE 6 0 - 1 2 0 PSlG
\

INSTRUMENT AIR FLOW 1 0 SCFM

8.0 OPEIXATING AND PERFOILMANCE DATA

C V 2 PERFORMANCE DATA

MODEL: C V 2 29MX3

DESIGN

GAS AIR

NOMINALINLET CAPACITY (ICFM) 2826

BAR0,ME-TRIG PRESSURE (PSIA) 13.94

INLET TEMPERATCIRE ( OF)

DISCHARGE PRESSURE (PSIG)

RATED SPEED (RPM) 2970

COOLING WATER INLET TEMPERATURE /OF) 104

COOLING WATER FLOW(GPM1

iST STAGE AIR COOLER

2ND STAGE AIR COOLER

AFTERCOOLER

OIL COOLER

'TOTAL {ALL COOLERS)

8.0 OPERATING AID PERFORJZAHCE DATA
 T r o u b l e S h o o t i rig
A t t a c h m e n t 1 - Star-I;-LIP Compressor

---- ... .. ----- .

I TROllBLE -1 -
CHECK POINT NOS.

I .................... -
......................................................................
Oil pumpirig
- -I 1-8-10- 12-18-24-25
I
I ...................................................................
Knocks or rattles .................. ; 2-3-19-20-21-22-23-25
I Water hantrner (or1 unlls equipped wlth water-cooled altercool~!rs)...........26 I
1 Air de!lvery has dropped off ................................................................. 1.2-6-18-20-24-25
Intercooler s:rfely valve pops ....................................................................
20-21-29
Trlps molor overload or draws excessive current ...................................... 14- 15-16- 17- 113-20-22-23-25
9-
Waler In lrarne or rustlng In cylinders ...................................................... 12- 13
Machlne won't unload ......................
.....................................................
21
Excessive slnrling and slopping (auto slarl) .............................................4-6-7-14
I Compressor doesn't unload when stopped .......................................... 18
I
I Compressor runs excessively 1101 ............................................................. 2-5-7-1 1-20-27 I
- I
I
I
Compressor wori'l come up to speed .......................................................15- 18
Lights flicker when cornpressor rurls ........................................................ 15-16
~
I

Abnormal pislori, ring or cylinder wear ...................................................... 8- 1 1-12-28

.-
--
Check

I
I -
Polril Nos.

1. ............
T ~ o u b l eCause
-
Clogged intake filter.
-----
I
I
1 2. ............ I'lcliel valve of single cylinder unit not operaling prolrc?l.ly. I
1 3. ............ 1-oose belt wheel or nlolor pulley or motor with excc!ssivr?erid play i r t sl~alt. I
1 4. ............ Receiver needs draining. I
5. ............ Air to Ian wheel blocked 011.
6. ............ Air leaks in piping. (on machine or in outside sysleni)
7. ............ FIect?ivercheck valve leaking.
8. ............ Oil viscosity too low.
I 9. ............ Oil viscosity loo high.
10. ............ Oil level loo high.
1 1. ............ Oil level loo low.
12. ............ Detergent lype oil being used. Change 10 not)-deletgellt type with rust and oxidalion inhibitor.
' 13. ............ Exlremely light duty or localed In damp humid spot.
14. ............ Sliotlld be equipped with conslanl speed conlrol due to sleady air demand.
15. ............ Check line voltage, motor terminals for good contat:l, liglil slarler connections. proper slarler healers.
16. ............ Poor power regulation (unbalanced line). Consult wilh power company.
17. ............ V-Bells pulled excessively tight. .
18. ............ Leaking or maladjusted centrifugal unloader pilot vnlve, or defeclive " 0 " Ring in pilot valve.
19. ............ Carbon on top o l pislon.
20. ............ Leaking, broken, carbonized or loose valves or reslricletl air passages.
21. ............ Discharge unloader valve dirly, seats worn.

I 22.
23.
24.
............
............
............
Worrl or scored connecling rod, pislon pin or cranlq)iri I~ctsliings.
Defective ball bearing on crar~kshaltor on rnotor sh;tft. I.oose motor lari.
Piston rings broken or no[ sealed in, end gaps no1 r,la!~clered,sluck in grooves, rotrgh. scralclled or ex-
cessive end gap (over .20" worn) (.SO8 mnl) wlien Ilie r i ~ i gis urider 5" in diarlieler, or (over ,032" worrl)
(.(I12 mm) when the rings are over 5" diameter, or sirlt?clearance (over ,006") (. 152 mln).
1 25. ............ Cylil-~dersor pislons scratched, worn or scored.
I
26. ............ AtJic~strate 01 water llow through altercooler.
27. ............ Wrorig direction of rotation.
28. ............ Extremely dusly almosphere. Need more ellective :iir inlet mulllar and cleaner
qo nh~--~:*,,.
--I-#,. ,,-I,.-
 1 - r o u b le Shoo-t;i t-1g
A t t a c h m e n t 2 - Main Cotnpressor

SYMPTOM
-POSSIBLE CAUSE --
C O ~ R E C T I V EACTION

Fail l o Start " Failure l o clear shuldown or inlellock Correct shutdown or interlock condition
devices. lhal is iriclicaled by panel lighl.
No prirnarypower lo slarter. Cht!ck vollage l o slarter. Check fuses.

No conlrol panel power l o compressor Clirxk vollage l o panellslarter. Check

conlrol panel or slarter. cor~lrollranslornier

Loose or corroded connection or deleclive Check connections. Clean, tighten and

power cables. replace as necessary.

Deleclive motor siarter or slarting circuil. Tro\.rbleshoolstarter per manufaclurer's

recornniendalion.
Inelleclive lrriproper adjuslmenl of prelube pump reliel Adjrlsl relief valve for correct
Prelube Pump valve. pressure.
Pump no1 running. Troubleshoot purnp starter. Check lor
prollar vollage.

Deleclive motor. Repair or replace motor.

Cseleclive pump. Reoair or replace pump.

N o seal air. Eslablisli seal air.

High Oil Low or n o water flow l o oil cooler. Eslablisli correcl waler flow.
Temperalure
tligher waler lemperalure lhan realized. Take riecessary steps lo lower Ihe waler
supply leniperalure.

I~nproperlemperalure devlce selling. Calibrale inslmrnenl.

Dirly or plugged oil cooler on waler side. Clcnn cooler lubes. Provide water
str;~irit!rs as necessary.

Low Oil Improper adjuslmenl o l syslem pressure Adjust syslem pressure relief valve
pressure reliel valve. lor correcl oil pressure.

Leaking or pinched 011 line. Reoair or replace oil line.

Ilirly oil filler. Rr!l,laco oil liller elernenl.

Ilefeclive main oil pump. Rcllair or replace main oil pump.

I-ow oil level. k l r l oil. .

 Attachment 2
- - -

High Air Low or rio waler llow lo alr cooler. Eslablir;h correcl waler flow.
~empbralure .
Hlgherwaler lemperalure lhan reallzed. Take necessary steps lo lower Ihe waler
supply Icrl~pc!ralure.
Improper lernperalure device setling Calibrale irislrumenl.
Dirty or plugged air cwler on waler side. Clean wnler passages In cooler. Provide
waler slrairiers as necessary.
Low Seal Air Low l r ~ s l r ~ ~ mair
e npressure.
l See 'Low lrislrumenl Air Pressure' below.
Pressure

lrnproper adjuslmenl of seal air pressure Adjusl regulalor to oblain conecl seal
regulalor air pre!;sure.

Worn seals. rep lac:^ seals. (Consull Ingersoll-Rand

Cornpi~~iy.
Low Inslhrnenl Air No supl~lypressure. Eslablish irislrunienl air supply pressure
Pressure Pinclied or leaking air lines. Repair or replace air lilies.
Improper adjustment ol air rqulalor. Adjusl regirlalor lo oblain wrrecl
inslrur~~orrl
air pressure.
High Vibralion Low oil lernperalure. Allow warm-up period lor oil.

!or11 coupling. Lubricale. Replace coupling.

flolor unbalance due lo build up. Cornpi~rereadings with log and consull
Ingersoll-RandCompany.

Rolor unbalance due lo damaged aero Consull Irigorsoll-Raid Company.

parts.
Induced vlbralion from driver. Consult drivor rnanulaclure or Ingersoll-Rand Co.

Fail lo Load Mode !;elector switch InUNLOAD posilion. Turn sclloc?or swilch lo desired operaling
mode.

LOW sel poinl on pressure conlroller. Adjusl conlroller lo desired operaling

pressure.

Bypass valve no1closed or inlel valve
Look lor air leaks, proper lunclion ol
solen~~irlvalve and load delay limer.
During low demands inlel valve .
.
willnc~llully open.
 ; Attachment 2

Low Syslem hlr Compressor no1loaded. See above.

Pressure

Ilirty inlet liller. Change filler elements.

Low surge. See "Conlinual Surging" below.

Grealer demand lhan realized. Repair ALL air leaks. Turn oll unnecessary
derriarids.

Conlinual Surge Disctiarge block valve closed. Operi block valve.

1rnorc)percalibration of surge sensor. Calil~raleinslrurnenl. Insure surge

sensor swilch is no1sluck.

C)irly irilel liller. Cii;~ngcfiller elemenls.

I~nproperadjustment on maximum Adj~rsll o suil sile condilions.

lhrotlla poinl.

I-liyh interslage air lemperalure. Estal~lislicorrecl waler flow l o air

coolers.

kliglicr water lernperalure lhan realized. Takeriecessary sleps lo lower Ihe water
supply lomperalure.

Worn aerodynamics parts. Corisull Ingersoll-Rand Company.

Excessive Power Lower ambienl lemperalure than realized. Reduce compressor load. Consull
Consumplion Ingersoll-Rand Company.

Low primary vollage. . Consull power company. Check power

source.

neduclion in molor efficiency. Consull riiolor manulaclure.


I.ligh pressure drop across
dryer.
I--
I Inlorrnediale air
Bubbles In sigtil glass.
1 1
Yellow sigh! glass.
,
1 'rl'ermediate air
lemperature hi tier llian
indicated in ~ a % l V.
e
SYMPTOM(S) POSSIBLE CAUSE
I.In1 roper adjus\riienl of
CIGBG.
.. ..-- --
2. Inlet air ternpor;rturn
Suclion lempetalure higher higher Ilian 130.F.
lhan 5 5 ' F .
3. Excessive airllow
. ..- --- -
4. Leak in relrigornlioii
systern.
. - -.- -
I3elrigerant dischar e Low ambient lernprlr:~li~re. Consul1 your local dislribulor.
];;!lyrature lower I ian 9
- . --- --
1. Condenser foulotl or
clogged. .-. - -- -
2. Fan motor slopr~adair-
cooled wnderiserr, o ~y).i
-..-.-- ...
3. fnmrred fan cyf;lir~
adjustmant (air-moles
I4slrigerant discharge condensers only).
-.-.- - -- .
l e r r i ~ r a l u r ehigher than
4, fnfel air lempernlrrre loo
220 F.
high.
5. l n m r r e d walqr valvn
adjustment (water-wolnd
condorisers only).
". --
liilet air temperature lower Low ambienl temperalr~re.
\liar1 40'F.
. -.
Excessive airflow (may Dryer improporty sized.
also cause water
downstream of dryer).
..
Dryer icing up. Suction lemperaluro lower
than 25'F.
lo~iiperalurebelow 32'F.
Dryer icing up.
- -
Iritormedia(e air 1. Loss of rslrigerar~t
Lorriperalure loo high. chargo. Flelrigsranl
Frostlng of mnipressor or compressor cycles or1 low
pressure conlrol.
rio molrng. Refrigeranl
suclion temperature loo 2. Refri orant liller/(lrynr
higli. 8
p b x l e UP. - '
llelrigeranl discharge Waler in relrigaratiori
terliperature hiyher tlian system. Leak iri cllillnr or
;!20 F. Retrigorant suclion walercooled condi~risiir.
t a r ~ i ~ r a l utiiglier
re than
65.
~ ~
Uubbles in sigh[ glass.
1. Loss ol rnlrigeri~~il
charge. Relrigerarit
cycles oti low
pressure conlrol.
2:Refri erant filte~/dryor
p k x l e UP.
.----.
--- REMEDY
. ... . .
1 . Remove cap from IHGRV and scrsw or11
. -. ...
1-IGBV 14 turn with nn alleri wrsricli l o
fowor suclior~Iernperalurn lo Iho InvwI
listed in Ilia Relrigsranl Flow section.
--
2. Redl~ceaftercooler disclinrge
lernperature l o dosign wilditions (130'F
-.- - max.).
--
3. Chock airflow and syslem capacily.
Roducr, aidlow or resize and replace
syslom.
--.
1. Locale leak; repair and rgchargs.
- ---
.
1. Clean or replace condenser.
-----
I-
2. Replace Ian motor.
-
3. Consult your local dislribulor.
--
4. C1isck lernperature of inlel air. Reduce
lo dssign cwndilions.
5. Adjust water valve to 2 10 psig. To
decrease the pressure, turn the slollad
square extension on the wafer regulating
valve (at Ihe compressor inlet) clockwi~e.
incressing lha waler Ilow. 1.0 lncreasa llie
prossurn. turn lhe oxtension
courilorclockwise.
Turn off dryer urtlil ambient lampsrnltjr?
exweds roquired pressure dew poiril.
---- ----
Check airflow a r d dr er capacily (sns
l-abl~11, Reducn airlbw o; resize and
replace dryer. ---
.-. .
neniove cap from tlGBV and screvr i r i
FIGBV 1 4 Iurn w i ~ han allen wrench l o
raise suclion l ~ m p e r a llo~ IIie
l ~ levol
listed in (lie Relrigerant Flow section.
-- . - -
I. Adjust o qraling condilions to moel
sizina.,con&ions.
--
2. Remove cap froni I-IGBV and scrsw in
I-1GDV 14 turn with an allen vrraricli l o
raise suction lenip~raturelo tlie level
listed in Ihe Refrigeran~Flovr ssdiori.
I. Locale lo*. Repair and recharge.
2. Replace lillerldryer.
-
Localn lnak. Repsir leak or replace cliiller
or condoriser.
1
I. Locale leak. Repair arid recliarge.
2. Replaca lillerldryer.
- --.-
-.- ..
 Trouble Shooting
Attachment 3
I I alltomatic drain valves
(AUVs).
IIJLET AIR Ism erature
indkilling IigIit iaslies. IAT
is ot~lsidenormal range or
IA-rreacties alarm set
ooinl.
Liqilid water entering dryer.
Exc~>ssiveairflow (may
also cause high pressure
drop).
I'lolrigerant compressor cul
o t ~I:I~
l high relrigoranl
discliarge pressure control.
I-
C ~ n ~ p r e s s culs
o r out on
iri~ernaloverload.
I C:orripressor windings read
opon or shorted.
Inlcrrmediate air
lerrlperalure h' her than
iridicaled in ~ a l l e
IV
- -..-
tIIC;t-l EVAP light on.
- A i r Oryer-
...--..--- ------.
POSSIBLE CAIJSI! 7 REMEDY 1
ADV lailrrre or Disnrantle AUV; clean, repair or replacr!.
accumulation 01 dirt i r i AIIV.
---. . . -..--..- - --.- .-- -.. ..-. - - -
Altercooler ~nallurlcliori. Check allercooler discharge lemperatrrre.
Reduce lernpsrature to 120'F max.;
reduce airflow il l e m ,eratore is above
100.F. (Sac Siring Jerificalion.)
Altercooler drairi valve Uisnianlle allercooler drain valve; cleari.
mallundion.
- - .- ..- ...-
Dryer improperly si;.c)tl.
r e ~ l a c edryer.
1. Conclnnser l o u l e ~or
l 1. Clean mnderiser coils (see
Maintenenace, Monltily).
2. Fan molor sroppt?d. 2. Repair or replace lari motor.
-. ...-- - - -
3. Inlet air lemperalt~ratoo 3. Check altercooler discharge
high. lempratt)ro. R d u c e lemporature lo
120'F max.; reducs airllow if lernpsralurs
is Iiialier Illan 100'F (see Airflow section)
-. ..-. -.. .---- - --. - - - -- .
I . Air in relrigeralior~ 4. I-lave relri eration niechanic localc! and
repair leak. &charge.
....-..--
5. Wrong relrgerarit in 5. Rsplace refrigerant with R22. Reset
system. high discharge pressure switch.
....-.- -- .-
6. Ambient air lerii~~flral~.rre6. Vent compressor room lo oulside.
loo high lor air-wolod Resel high/low rnfrigeranl cutout or1
compressor. rolrigoralion sysleni.
....--- --.-- --
7. Altercooler coolarlt air 7. Raflle or vent l o outside air. Reset
blowing or1 air-coolrd highnow relrigeranl cutoul or1 relrigernliori
condenser. syslem. --
1. inadequate ventilntior~01
aircooled compressor.
compressor is cool.
.....-- ---.
2. Insullicienl coolirig water
lor wafer-cooled
compressor.
.-. - .--- . --
3. Leak i n relrigeralbn
system.
compressor is cool.
.--.--
...
4. Incorrect adjrrstrr~nrtlo l
relrigeralion curilrol vnlvos..
Compressor burnod onl. Have refrigeration mechanic check and
replace. I
Excessivs airflow or ti InlAT does not come into range when
lluctualing inlet wndilioris. inlet conditions stabilize. check arid
reduce air llow or resize and replace dryer.
.-- -- -.
1. Leak i n relrigeratiori 1 1. Locale leak; repair and recharge.
-
system.
-
2. lrnproper adjc~sll.rienlof 2. Renlove cap from HGBV and screw out
HGBV. I IGBV '/t turn with an alleri wrsrich lo
lownr suclion lernperatr~relo the level
listed in Ihe Relrigeranl Flovl section.
3. Air or nonmndenr,ables 3. Locale leak; Apair and recharge. I1
in relri. eralion syslsrn. chillnr rnusl be replaced. wrisult your
~ossibqeleak in cliiller. local dislribulor.
- PROBLEM

No condensate lrom
aulornalic drain valve
(ADV).
Valve continuously venting.

Vdve not cycling

-
Elo response when lest
button is pushed.
POSSIBLE CAUSE
1. Clogged diapl1r;rgnl.
-.- ----- I.Clean diapliraqm.
2. Short in electrk;~l
compononl.
1. No electrical power.

2. Timer rnallunctior~.
3. Solenoid mil
malfunction.
1. Clogged ports.
-. .--.---

1. No electrical power.

2. Timer mallunclion.
...-----
I
I
REMEDY

2. Replace timer assembly.

4. Clean p r t s .
--
3. Replace solenoid coil.
. . ..

2. Chnck and replace conriector or 1i111or

assembly.
1. Check ahd correct powsr supply and
conneclions.

1. Check and correct power supply and

I Es
SEAUNC AIR
COMPRESSOR
EzEl
AIR
DRYER
n
tld (gOlEP
'9

11. urn, IW m
YL *~rnm~muR
uIC m CWHDI+mnn.W L
5 onrurr

mm

A MvTGm W PTE~~ACCNTRAK
DIIC~.LL.L..II.II cunur A urn-:
%Uu.
U A *MIA. -Way.

SERVICE AIR & INSTRULIENT