Centac: C1000 Planning & Installation Manual

CENTAC ®
C1000 Planning & Installation Manual
C.C.N. : 80446081
REV. : A
DATE : JULY 2010
2 C1000 PLANNING & INSTALLATION MANUAL
Table of Contents
Table of Contents ________________________________________________________________ 2
About This Manual _______________________________________________________________ 4
Product Description ______________________________________________________________ 4
Safety __________________________________________________________________________ 4
General Workplace Safety ______________________________________________________ 4
Documentation, Decals & Tags __________________________________________________ 4
Personal Protective Equipment & Attire ___________________________________________ 4
Handling & Transporting _______________________________________________________ 4
Installation Materials & Components _____________________________________________ 5
Electrical Hazards _____________________________________________________________ 5
Product Hazards ______________________________________________________________ 5
Explanation of Safety Signal Words ______________________________________________ 6
Safety Labels _________________________________________________________________ 7
Receiving/Handling/Storage _______________________________________________________ 8
Receiving ____________________________________________________________________ 8
Handling/Lifting _______________________________________________________________ 8
Storage ______________________________________________________________________ 9
Installation Planning _____________________________________________________________ 9
General ______________________________________________________________________ 9
Site Layout ___________________________________________________________________ 9
Indoor/Outdoor Installation _____________________________________________________ 9
Foundation __________________________________________________________________ 10
Leveling ____________________________________________________________________ 11
Grouting ____________________________________________________________________ 11
Air Piping______________________________________________________________________ 11
Inlet Air Piping _______________________________________________________________ 12
Remote Bypass Air Silencer/Piping _____________________________________________ 14
Local Bypass Air Silencer/Piping (Optional) ______________________________________ 14
Expansion Joints ____________________________________________________________ 15
Discharge Air Piping __________________________________________________________ 15
Discharge Air Piping for Multi-Compressor Installation _____________________________ 16
Receivers ___________________________________________________________________ 17
Control Air Piping ____________________________________________________________ 17
Instrument Air Piping _________________________________________________________ 18
Water System Piping ____________________________________________________________ 18
Cooling Water Piping _________________________________________________________ 18
Air Cooler Vent Lines _________________________________________________________ 20
Condensate Drain Piping ______________________________________________________ 20
80446081-A EN ingersollrandproducts.com
C1000 PLANNING & INSTALLATION MANUAL 3
Electrical Connections___________________________________________________________ 22

Introduction _________________________________________________________________ 22
Control Panel Power __________________________________________________________ 23
Optional Switches ____________________________________________________________ 25
Lubrication ____________________________________________________________________ 26
Recommended Lubricant ______________________________________________________ 27
Physical and Chemical Requirements for Techtrol Gold III Coolant: __________________ 28
Reservoir Capacities__________________________________________________________ 29
Standard Oil Cooler and Filter Data _____________________________________________ 30
Weights and Dimensions_________________________________________________________ 30
Recommended Tools ____________________________________________________________ 31
Checklist Summary _____________________________________________________________ 32
Customer Assistance____________________________________________________________ 35
Notices and Disclaimers _________________________________________________________ 35
Copyright Notice _____________________________________________________________ 35
Proprietary Notices ___________________________________________________________ 35
Disclaimers _________________________________________________________________ 35
About This Manual

The purpose of this manual is to provide planning and installation guidelines for the compressor. Information on
the operation and maintenance of the compressor is included in the Operation Manual (CCN 80446099).
In addition to this manual, you should have the following documents for planning and installation purposes:
 General Arrangement Drawing

 Electrical Schematic
 Process and Instrumentation Diagram
 Motor Outline and Data Sheet
Product Description
An air compressor takes in air at atmospheric pressure and delivers it at a higher pressure.
Safety
WARNING
Failure to observe these safety guidelines could expose personnel to potentially hazardous situations
which, if not avoided, could result in death or serious injury.
General Workplace Safety

 The information presented in this manual should be used in conjunction with your workplace safety
program.
 It is the responsibility of each individual to ensure that they work in a safe manner and in compliance
with any local law or site regulations.
 Keep the work area clear of hazards.
 Assess hazards, make a list, and discuss with appropriate personnel.
 Know how to quickly contact emergency assistance.
Documentation, Decals & Tags

 Read and understand this manual before handling and installing this product.
 Locate, read and understand all hazard alert symbols, text decals and tags which point out items of
extreme importance to personal safety.
 It is your responsibility to make this information available to others.
 If you have any questions about safety or procedures not included in this manual, ask your supervisor or
contact any Ingersoll Rand office or qualified Ingersoll Rand distributor.
Personal Protective Equipment & Attire

 Wear personal protective equipment that is appropriate for the task (i.e. safety glasses with side shields,
respirator, hearing protection, cut resistant gloves, safety shoes) at all times.
 Long hair must be tied back or otherwise secured.
 Clothing must be close-fitting.
 Do not wear jewelry.
Handling & Transporting

 Do not attempt to lift the compressor package by the enclosure. Follow the instructions given in the
"Receiving/Handling/ Storage" section.
 The compressor bull gear is locked to the casing to prevent rotation during shipment. The locking bolt
must be removed prior to coupling the motor to the compressor.
Installation Materials & Components

 Do not use plastic piping, soldered copper fittings and rubber hose as discharge piping.
 Flexible joints and/or flex lines can only be considered for such purposes if their specifications fit the
operating parameters of the system.
 The piping to and from the compressor must be in accordance with the operative and safety
requirements of local codes.
Electrical Hazards
 Before installing the compressor, be sure that the electrical supply has been cut off.
 Use precautionary measures to prevent the possibility of applying power to the equipment when
installation work is in progress.
 An appropriate grounding strap should be attached to the baseplate and to suitable ground.
 The control panel (normally supplied) is equipped with high voltage components and may include the
main motor starter (if supplied). The power supply should be shut off before the panel door is opened.
Product Hazards
 Understand the hazards which arise from the presence of electrical power, rotating machinery, hot oil,
high pressure, high temperature, and hot liquids and gases.
 Ensure proper installation and care of protective guards, shutdown devices and overpressure protection
equipment.
 Never make any modifications, additions or conversions which might affect safety without the approval
of Ingersoll Rand. This also applies to the installation and adjustment of safety devices and valves as
well as to welding work on load-bearing components.
Explanation of Safety Signal Words

Indicates an imminently hazardous situation which, if not avoided, will result in
DANGER death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in

WARNING death or serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in

CAUTION minor or moderate injury or property damage.
Indicates information or a company policy that relates directly or indirectly to

NOTICE the safety of personnel or protection of property.
Safety Labels
The following labels are applied to the unit (where applicable):
Do not attempt to lift the

compressor package by the
Electrical shock risk.
enclosure. Damage to equipment
and personnel could result.
Do not breathe the compressed

Do not walk on the canopy roof.
air from this unit.
Instruction book location. Hot surface.
Do not remove the operating and

Do not operate the machine
maintenance manual from this
without the guard being fitted.
compressor.
Oil fill. Lifting point.
Direction of rotation of the

Automatic start compressor.
compressor gear.
Do not stand on any service

valve or other condensate
discharge parts of the pressure
system.
Receiving/Handling/Storage
Receiving
 Inspect the compressor for shipping damage before removing the compressor from carrier’s vehicle. If
damage or indication of rough handling is evident, file a claim with the carrier at once, and notify your
Ingersoll Rand representative.
 Remove only the shipping notice. Do not remove tags pertaining to lubrication, operation, and storage.
Read all tags and instructions.
 Document receipt of all items included with the compressor, but packed separately. Make a list of any
items that were not received and notify your Ingersoll Rand representative. Store all items either with the
compressor or in an appropriate secured area.
Handling/Lifting
 Refer to the assembly drawing (Figure 1) and the General Arrangement drawing for the lifting procedure
specifically suggested for your compressor.
 Ensure adequate rigging and lifting apparatus are available for unloading and moving the compressor to
the installation site. An overhead crane is suggested for this task. Lifting apparatus must be properly
rated for the weight of the compressor. Weight information is printed on a label attached to the shipping
container or to the compressor.
 Lift the compressor by the designated lifting points only. Lifting points have been provided at the corners
of the baseplate. Refer to Figure 1 and the General Arrangement drawing for location of the lift points.
 Do not use lifting eyes to lift the complete machine. Lifting eyes are for removing detached individual
parts (i.e. motors) from the machine.
 Use spreader bars to prevent damage to piping, tubing, gauges, and other accessory equipment.
 Do not work on or walk under the equipment while it is suspended.
Figure 1 — Lifting Diagram for Standard Unit
Storage
The compressor, as it is shipped from the factory (flanges banked and desiccant bags placed at inlet and
discharge), can be stored on a level surface in a climate-controlled area for up to 180 days after the ship date
tagged on the compressor unit without requiring long-term storage preparation.
The unit must be started within the first 180 days following shipment from Ingersoll Rand to assure the full 12-
month operational warranty after start-up. Store all loose parts in a controlled environment for adequate
protection prior to use.
If the motor is supplied with sleeve bearings, fill the motor bearing reservoir to the level recommended by the
manufacturer. Use a good grade of rust inhibiting oil. The shaft should be rotated a minimum of 10 revolutions
every month to keep the bearings lubricated. At the end of the storage time, the motor should be tested for
ground resistance before connecting to the power line. Specific motor start-up instructions provided by the motor
supplier must be followed.
If the unit is to be stored for periods longer than 180 days or in an uncontrolled climate, the unit will require
additional protection. Consult your local Ingersoll Rand representative for long term storage requirements and
extended warranty coverage.
Consider a unit in storage when:
 It has been delivered to the job site and is awaiting installation.

 It has been installed but operation is delayed pending completion of plant construction.
 There are long periods (30 days or more) between operating cycles.
 The plant (or department) is shut down.
Installation Planning
General
See the General Arrangement drawing for compressor/customer connection details. Contact your local Ingersoll
Rand representative for further information.
Site Layout
 The compressor should be located in an area that is accessible to operators and maintenance
personnel.
 Compressors installed in elevated locations or in pits should have stairways, catwalks, etc. for easy
access to the compressor.
 Adequate space should be provided to permit easy handling of the unit during installation (see the
General Arrangement drawing for compressor maintenance space).
 Provide floor space in the vicinity of the compressor where parts may be placed during periodic
inspection of the rotating elements and internal parts. Make provisions for clearance requirements
specified on the General Arrangement drawing.
Indoor/Outdoor Installation
 The compressor should be installed indoors. For an outdoor installation, protective measures are
necessary for the motor, control panel, and other items. It is important when the compressor is
purchased that Ingersoll Rand is made aware of plans and makes any necessary recommendations for
outdoor installation.
 If the unit is an indoor installation, a heated building is preferred.
 Provide adequate space for ease of handling during installation.
Ventilation
The compressor should not be installed in a damp or dusty atmosphere or where corrosive vapors may enter the
airend or driver.
On motor driven units, the heat radiated to air in the room will be approximately 6% of the total horsepower:
1 KW = 56.9 BTU/MIN (14.34 kcal/min)
1 HP = 42.4 BTU/MIN (37.8 kcal/min)
For an enclosed unit with integral air filters, additional consideration must be given to the room ventilation system
for the air ingested by the compressor.
In the case of nitrogen units installed in closed environments, suitable ventilation is required.
Noise
In areas where noise could be a problem, it is important to treat hard reflective surfaces in the area. Avoid
installing the compressor in an area with low hard ceilings and walls.
Foundation
The compressor foundation does not need to be massive but should be sufficient to provide support for the
compressor.
Since there are no out-of-balance forces, such as reciprocating or shock loads, all loads on the foundation may
be considered as static loads. If the compressor is to be located in an area with other machinery, it is essential
that vibrations are not transmitted to the compressor. Isolation pads are recommended in these instances.
A simple continuous concrete pad or steel support structure is recommended for each compressor. Precautions
should be taken to ensure a reasonably uniform base around the pad. Uneven settling or thermal expansion
could cause machinery misalignment. Appropriate bolting must be used to keep the compressor in place. Refer
to the General Arrangement drawing for location and size of anchor bolt holes.
NOTICE
The design of the foundation is the responsibility of the customer. These comments are offered as an aid
to assure a successful installation, but Ingersoll Rand cannot assume the responsibility for the design.
We recommend that the customer consult a specialist skilled in the design of machinery foundations.
Leveling
The compressor should be leveled at the time of installation. To level the compressor, place it over the anchor
bolts with the feet resting on steel wedges or shims, if necessary. See Figure 2.
The compressor may be leveled using a machinist level or transit level. When a machinist level is used, start at
one end of the compressor and work side to side toward the opposite end, placing the level on the machined
baseplate compressor pads. The compressor should be level from 0 to 0.5 mm/M (0 to 0.006 inch/foot).
After the compressor is level with snug (not tightened) anchor bolts, the coupling should be aligned. Some
baseplate distortion may be noted but this is unimportant as long as the machine pads remain level. Precise
driver alignment is not required until the time of start-up, but should be within 1.5 mm (1/16 in). Follow the
procedures found in the Operation Manual once the compressor arrives on site. The General Arrangement
drawing lists the values for the coupling alignment. Record the values obtained, but do not dowel the driver or
install the coupling spacer.
Anchor bolt
Baseplate/
Cooler feet
Leveling wedges Leveling shims
Foundation / pad
Figure 2 — Wedge and shim placement
Grouting
While not required, grouting is the most common method for permanent installation of rotating machinery. Fill the
area between the baseplate and foundation with a minimum of 2.54 cm (1 in) of grout to create a uniform bearing
surface. Common grouting materials are non-shrinking concrete and epoxy type grouts.
Grout is installed in the space below the baseplate beams after preparation of the foundation surface by chipping.
After the grout has set, any wedges or shims used to level the unit must be removed and the remaining spaces
filled with grout.
If grout is not used, anchor bolts should be tightened with leveling shims in place. Shims should be around each
anchor bolt to prevent distortion of the base.
Air Piping
This compressor has 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. Adequate
piping supports are necessary to prevent excessive dead loads on the flanges of rotating machinery.
Piping alignment to the compressor mating flanges is essential. The piping must be installed and supported to
avoid strains on the casing. Misalignment, which is a frequent cause of vibration, can often be traced directly to
piping strains. Three sources of piping strains are:
 Dead weight of the piping itself

 Expansion or contraction of the piping as it undergoes temperature change
 Pressure within the piping
If any pipe needs to be levered or pried into position to match up the flange face with the compressor, there will
likely be excessive pipe strain. A properly matched pipe flange will have just enough space to install 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.
All piping connected to the compressor should have provisions for compressor maintenance by means of flanged
sections or unions in the connecting pipe. A sufficient number of removable sections of pipe should be provided
to allow ease of maintenance and repair.
Summarizing, a satisfactory piping arrangement can normally be obtained by giving proper attention to:
 Providing adequate support for all parts of the piping system.

 Allowing for expansion in a manner that will avoid piping strains on the compressor.
 Installing a sufficient number of anchors in the piping system so that direction and magnitude of
expansion are controlled.
 Designing the inlet and discharge piping so as to provide smooth flow with minimum pressure drop and
uniform velocity over the entire area of piping.
NOTICE
The design of the piping system is the responsibility of the customer. Data and comments are offered as
an aid to ensure a successful installation, but Ingersoll Rand cannot assume responsibility for its design
or installation. We recommend that the customer consult a specialist skilled in the design of piping
systems to supplement and interpret the piping information and to ensure a successful installation.
NOTICE
The inlet pipe and filter must be inspected before startup by an Ingersoll Rand factory certified service
representative.
NOTICE
All air and water piping to and from the inlet and discharge port connections must take into account
vibration, pulsations, temperature, maximum pressure applied, corrosion, and chemical resistance.
Where compatibility questions may exist, contact your Ingersoll Rand representative.
Inlet Air Piping

It is imperative that the compressor receives clean filtered air to function correctly with low maintenance. Inspect
piping for cleanliness prior to installation and before start-up.
Maintenance
It is advisable that you install spool pieces that allow the casing sections to be removed and the piping to be out
of the way of personnel for maintenance. The inlet pipe will be removed for inspection at start-up.
The importance of always operating the compressor with clean air inlet piping must be stressed. No compressor
will accept the injection of foreign material into the operating components without possible damage or loss of
performance.
Inlet Air Filter

The high efficiency two-stage inlet air filter furnished by Ingersoll Rand should be mounted by the customer at a
suitable location. For adverse environmental conditions, a more efficient inlet air filter is recommended. Consult
an Ingersoll Rand representative for assistance.
Routine inspection of the filter is recommended and the addition of instrumentation to indicate pressure drop
across the filter elements is also suggested. When this drop increases substantially, the elements should be
cleaned or replaced.
Remote Inlet Air Filter

When the filter is mounted at a remote location with the inlet air piping supplied by others, the following
recommendations should be observed.
The remote inlet air filter should be, at minimum, a high efficiency unit designed to remove particles at 2 microns
or larger. For adverse environmental conditions it is recommended that you use a special filter, such as:
 A 0.3 micron inlet air filter

 An inertial spin filter
 A chemical type filter

Check with your Ingersoll Rand representative for specific filter information.
The air filter should be located as close to the compressor as possible to minimize pressure drop. If the filter is
located outside the compressor building, the inlet housing should be at least 2.4 to 3 m (8 to 10 ft) above the
ground or roof and 1.8 m (6 ft) away from the side of a wall. See Figure 3.
Access to the filter should be provided with ample room around the filter for maintenance. A permanent platform
should always be built around elevated filters to provide safety for personnel assigned to changing filter elements.
For best performance, the inlet air piping should conform to the following recommendations:
 The inlet piping, from the inlet filter to the compressor, must be clean and made from a non-rusting
material such as stainless steel, aluminum, or PVC, and suitably flanged so that it may be inspected in
sections.
 Inlet piping should be short and direct, with the combined filter and piping pressure drop less than 0.3
psi (2.1 kPa[a]).
 Always use long radius elbows.
 Transitions in pipe diameters should be gradual.
 Any horizontal run of pipe should be installed so that condensation in the piping will run away from the
compressor.
 Drain valves should be installed in the inlet piping at low points to allow the removal of condensation.
Local Inlet Air Filter (Optional)
When a sound enclosure is furnished with the compressor, the air filter may be mounted on the enclosure. The
filter is mounted and piped to the compressor intake and no additional field installation work is required.
Inlet filter
Work platform 8 ft. (2.4 M) min.
Roof line
Max p 0.3 psi (2.1 kPa[a])

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 3 — Inlet Air Piping – Air Filter
Remote Bypass Air Silencer/Piping

Atmospheric bypass piping vents the compressed air when the compressor is running unloaded or at partial load.
Bypass piping should be well supported to minimize loading on the compressor flange. Care should be taken in
the piping design so that all alignments can be made in the piping.
A bypass silencer should be installed in the atmospheric bypass line to reduce noise. The silencer is furnished
with the compressor package and is customer mounted. The silencer has acoustic absorption material at a
controlled density. The silencer is usually installed close to the compressor and the vent piped outside.
Alternately, the silencer may be installed outside the building. Consult the certified drawings for complete details
of the silencer.
For sound attenuation in piping, a straight run of pipe from the compressor flange, at least 8 pipe diameters long,
is suggested before entering a long radius elbow. See Figure 4. The silencer should be kept as close to the
compressor as possible and the total length of pipe kept short. In noise critical areas, the discharge piping from
the silencer may be lagged to further reduce sound.
Discharge deflector
Roof line
Hanger (typ)
Silencer
Alt. side wall discharge

Drain Long radius elbow
Minimum
8 pipe
diameters
Bypass valve
Figure 4 — Model Bypass Pipe

Discharge piping from the silencer should be sized so that the maximum backpressure on the silencer is 5 psi or
35 kPa (a). Bypass piping to the silencer should be of the same diameter or larger than the bypass valve. Piping
from the bypass silencer should be of the same size or larger than the silencer discharge. Refer to the certified
drawing for complete details of silencer.
The bypass piping should be suitably flanged so that a minimum amount of pipe needs to be removed during
major maintenance. This will reduce maintenance time.
The end of the pipe should be turned down or have a short horizontal run of pipe to prevent rain and snow from
entering the bypass piping. Expanded metal should be installed on the end of the pipe to prevent large objects
and animals from entering the pipe when the compressor is stopped. To remove condensation from the piping,
install a drain in the lowest part.
Local Bypass Air Silencer/Piping (Optional)

When a sound enclosure is furnished with the package, the silencer may be mounted in the enclosure. The
silencer is mounted within the enclosure and bypass air is re-circulated to the intake of the compressor. If an
aftercooler is not part of the package (hot air discharge), then this option is not available.
Expansion Joints
With proper piping layout and installation, expansion joints may not be required on all compressors. Expansion
joints are required on all hot air discharge compressors (no internal aftercooler). Refer to the turbine
manufacturer manual to determine if expansion joints are required for the turbine.
Expansion joint installers must consult the manufacturer’s instructions to ensure correct installation.
WARNING
Improperly applied and/or installed expansion joints can result in severe injury, death, or property
damage due to over stressing and fatiguing of the bellows material.
NOTICE
While Ingersoll Rand may recommend or even supply an expansion joint, proper installation is the
customer’s responsibility.
Discharge Air Piping

For the best performance, a straight run of pipe which is at least 3 pipe diameters long should be interposed
between the discharge check valve and a long radius elbow to allow for smooth operation of the check valve. The
piping should be the full size of the compressor discharge connection. Where pipe diameter conversion is
necessary, the transition should be gradual. The use of long radius elbows is recommended and piping may be
sized by normal methods.
On all compressors, it is necessary to install a spool piece that will allow parts of the compressor to be removed
and piping to be out of the way of maintenance personnel. The customer should install a block valve in the
discharge line to isolate the unit for maintenance. A safety relief valve is installed between the compressor
discharge and discharge check valve. See Figure 5.
NOTICE
Drain valves should be installed in piping low points to remove condensation, which might form during
periods of shutdown. Piping should be designed so that the condensation will not drain back to the
compressor.
WARNING
The use of plastic piping, soldered copper fittings, or rubber hose, as part of the discharge piping is not
recommended. In addition, flexible joints and/or flex lines can only be considered for such purposes if
their specifications fit the operating parameters of the system. Failure to adhere to these
recommendations can result in mechanical failure, property damage, and serious injury or death.
NOTICE
It is the responsibility of the installer and owner to provide the appropriate service piping to and from the
machine.
Block valve
Safety valve
Pipe hanger
“CA” tap in. To be located a minimum

Discharge temperature
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.

Located a minimum Package
of 3 pipe diameters mounted
from check valve check valve
Low point drain
Figure 5 — Model Discharge Pipe

Adequate piping support is needed to prevent excessive dead loads on the compressor flange. Provisions should
be made in the discharge piping so that all alignments are made in the piping and not the compressor.
Discharge Air Piping for Multi-Compressor Installation

The steep performance curve of the compressor allows for operation in parallel with piston or rotary screw
compressors. See Figure 6. However, piping layout design should isolate the compressor from the pulsations in
the discharge produced by these compressors. Piping the compressor into the discharge header downstream of
the pulsation bottle or receiver effectively eliminates pulsation problems.
Fast valve operation allows the lagging compressors to supply huge quantities of air at system pressure. Proper
consideration to the entry of this added capacity into the system will eliminate control or surging problems
commonly associated with this type of installation.
Discharge piping from the compressor should enter the system header by way of long radius elbows or at an
angle in the direction of flow. By staggering entry into the header the added capacity will have no detrimental
effect on the other units already on line.
Air compressor connections and sizes are located on the certified customer prints. Refer to the General
Arrangement Drawing and the Process and Instrumentation Diagram for further detail.
Recips or Recips or
Centac Centac
Screws Screws
Receiver
System Header
Flow Long radius elbow
Angle with flow
Flow
Centac Centac
Centac
Centac
Figure 6 — Centrifugal and Positive Displacement Piping Arrangement
Receivers
Receivers store compressed air for systems in which air demand fluctuates over a short period of time. A
properly sized receiver will decrease the number of times the compressor loads and unloads. This will increase
the compressor's efficiency and decrease wear on valve components.
Receivers can be installed as "Wet" (before the dryer) or "Dry" (after the dryer) receivers or in both locations.
Contact your local Ingersoll Rand representative for assistance in properly sizing and locating this equipment.
A receiver may also be used to isolate centrifugal compressors (or other equipment) from pulsations created by
positive displacement air compressors. A pulsation bottle may be needed to eliminate pulsations more effectively.
Control Air Piping

The control air pipe penetration is made at a minimum of 10 pipe diameters downstream of the discharge check
valve in the discharge pipe. The control air line connects to the control panel bulkhead fitting marked ‘CA’. The
control air line should be a minimum of 1.27 cm (1/2 in) diameter, made of a non-rusting material such as
stainless steel, aluminum, or copper. If the line is to be installed in a horizontal run of pipe, it should be located at
the top of the discharge pipe to minimize condensate or debris buildup in the line. The control air line should be
routed to the control panel in such a manner that the line will not have to be disconnected in order to perform
major maintenance. A drip leg with a drain valve, which can be used to remove condensate, is recommended as
part of the customer’s control air line.
Figure 7 — Control Panel Connections
Instrument Air Piping

Instrument air must be provided for the operation of the pneumatic control valves and for the seal buffer air. The
air used must be clean dry instrument quality air. For best results, piping should be connected to a refrigerated air
dryer and filter prior to connection on the unit. The Air compressor normally requires 10 SCFM (0.33 m3/m) of air
per stage at 60-120 PSIG (414-827 kPa) .
The final filtering medium should be rated at a theoretical efficiency of 99.9999%, particle size of 0.01 micron,
and a minimum or 25 SCFM (0.82 m3/m). This filter should be located close to the control panel. An isolation
valve may be located ahead of the filter.
Piping from the instrument air source should be constructed of 1/2 inch minimum non-corroding material to limit
the possibility of corrosion products entering the system. Instrument air piping connects to the control panel at the
1/2 inch NPT bulkhead fitting marked “IA”.
Water System Piping

The water piping section consists of the following topics:
 Cooling water piping – provides cooling water to the air and oil coolers of the compressor
 Cooling water specifications – gives recommendations for clean water
 Air cooler vent and drain – connects air vents and cooler drains
 Condensate drain piping – provides a means of removing condensate from the moisture removal
sections
Cooling Water Piping

Unless otherwise stated, water flows are based on the design conditions of the compressor for rated discharge
pressure with 35°C (95°F) cooling water temperature. The package is furnished with the air coolers and oil cooler
pre-piped with one inlet and one outlet.
Sizing of water pipe to the package connections may be done by conventional methods based on the GPM flows
given. The pipe design must allow for a minimum water pressure of 2.4 bar (35 PSIG) and the maximum water
pressure of 10 bar (150 PSIG) (see General Arrangement Drawing for connection locations.).
The water manifold furnished with the package is sized to balance the water flow between coolers. An optional
throttle valve on the discharge of each cooler is available to aid in more precise temperature control. Gate valves
should be located at the inlet and discharge water manifold connections to allow isolation of the system when
required.
When throttle valves are supplied, adjustment is achieved by turning the valve. The stage outlet temperature and
oil temperature must remain inside the required limits when making adjustments.
Regardless of the cooling system used, a strainer should be installed in the water supply line.
Cooling Water Specification

Water used for cooling should be clean and free of corrosive elements. It is best that the water used is filtered
and treated to fall within the following specification:
 Total hardness expressed as CaCO3 should be less than 100 PPM.

 Acidity should be within the 6.0 to 8.5 pH range.
 Suspended solids should not exceed 50 PPM.
 The langelier saturation index should be between +0.5 and +1.0.
The 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 and this water will have a corrosive
tendency. Other factors that contribute to corrosion include:
 Temperature differences within a system.

 Changing operating conditions.
 Presence of chemical treatment in the water.
 Presence of dissolved oxygen in the water.
Air Cooler Vent Lines

Air cooler vents with valves are provided at the highest point on the air cooler bonnets. They are supplied to
ensure that the coolers are full of water when the compressor is operating and no air pockets form in the coolers.
If part of the cooler is starved for water, overheating may occur resulting in damage.
The vents should be opened prior to startup to ensure bonnets and tubes are full of water. See Figure 8.
Pneumatic and electric no-loss drain traps are available as an option. The pneumatic drains are pre-piped with
instrument air from the compressor control panel. The electric drains are pre-piped and wired with electrical
power from the compressor control panel.
Do not connect the vent lines together. When a closed cooling water system is utilized, casing vents should be
piped to the lower pressure discharge water line to ensure flow through the vent piping.
Figure 8 — Visual indicator of water flow through vent lines
Condensate Drain Piping

Air entering the first stage of the unit carries with it a certain amount of moisture. The amount of moisture
depends on the temperature and relative humidity. The maximum moisture content occurs on days of high
temperature and high relative humidity.
Moisture is removed from the air as it passes through each stage of compression. As the air passes through the
coolers, water vapor in the air is condensed and collected in the cooler shell. This condensation is removed by
condensate traps to prevent water carryover into the next stage of compression. Excessive water carryover will
create problems.
Condensate traps with bypass valves for each stage are factory installed. Each condensate trap must be
provided with a separate drain. In addition, each trap discharge should be piped to a drain that will allow a visual
check of the individual trap function. See Figure 9.
The location and size of the trap discharge connection is listed on the General Arrangement Drawing. The piping
arrangement is shown on the Process and Instrumentation Diagram.
If the unit is unattended or in a location where maintenance is minimal, a high-level condensate and shut down
alarm should be used. If the traps become clogged, water carry-over in the unit will result.
Compressor stage (Typ)
Pressure
Balance line
Float Condensate drain
Valve
Trap bypass valve

Air gap
Drain trough
To floor drain
Figure 9 — Standard Condensate Trap and Drain Arrangement
CAUTION
All air and water pipes to and from the inlet and discharge port connections must take into account
vibration, pulsations, temperature, maximum pressure applied, corrosion and chemical resistance. In
addition, it should also be noted that lubricated compressors discharge some oil into the air stream.
Therefore, compatibility between discharge piping, system accessories, and software must be assured.
Where compatibility questions exist, contact your nearest Ingersoll Rand office.
NOTICE
It is the responsibility of the installer and owner to provide the appropriate service piping to and from the
machine.
Electrical Connections
Introduction
The following electrical connections are required to the extent referenced in the supplied General Arrangement
and Electrical Schematic drawings:
 Control panel power

 Starter interface
 Main driver connections
 Heater contactor
 Prelube pump starter
 Current transformer
 Optional switches
WARNING
The equipment must be connected to properly grounded circuit by a qualified electrician following
applicable electrical codes.
NOTICE
The electric driven compressor is not equipped with an electrical disconnecting device. Ensure a main
line disconnect switch is installed. This device must be installed on the incoming line by the user.
Design and installation of disconnect, overvoltage, short circuit, and overload protection is the
responsibility of the customer.
Control Panel Power

The standard Air compressor control circuitry is designed for a 3-phase AC source Three-phase power at the
customer’s voltage is used for the prelube pump and oil reservoir heater. A control transformer is used to provide
120V 1-phase control power. The prelube pump starter, reservoir heater contactor and control transformer are
furnished inside the panel and pre-wired to the components.
To properly make electrical connections to the control panel, refer to the Electrical Schematic to identify the
proper terminals for wire connection, and refer to the panel outline drawing for conduit entry size. Incoming power
should be connected to the appropriate terminal blocks in the control panel as shown by the Electrical Schematic.
The C1000 packages have remote starters or optional electric accessories in which a number of external
electrical connections are required. The following illustration shows the electrical connections normally required
when the starter is separate.
1 = main switch, 2 = connection for motor supply, 3 = connection for CT signal for Ampere reading, 4 =
connection for compressor open contact for operating unit indication, 5 = connection for starter feedback contact.
Figure 10 — Electrical Connections for Separate Starter
NOTICE
Check the power supply and auxiliary terminal nuts for correct tightness before start-up, after three
months of operation and at least two times per year thereafter.
In these units with integral star delta starter, the factory pre-wires the CT (current transformer) in the control
panel. This CT is connected in a motor winding phase and senses motor phase amperage. The control panel 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 control panel needs for its control functions. The control
panel 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.
NOTICE
Refer to the electrical schematic contained in this manual to identify the terminals for the electrical
connections.
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.
Figure 11
CAUTION
Electrical line voltage micro-interruptions and voltage drops must be avoided. Serious mechanical
damages could occur to the main motor and to the electronic parts of control panel.
WARNING
The secondary of an energized current transformer (cti & ct2) must never become an open circuit. The
secondary must remain closed. Under open circuit conditions a hazardous potential (voltage) is
developed in a ct secondary when the primary has current.
WARNING
An appropriate copper grounding strap should be attached to the metal baseplate and to suitable ground.
WARNING
Do not disconnect secondary wiring during operation. Anytime secondary side of the current transformer
is disconnected from its load, a jumper must be placed across secondary terminals to prevent injury or
death of personnel and/or damage to equipment.
WARNING
An appropriate grounding strap should be attached to the motor and a suitable ground. Do not connect
to a plant ground circuit.
Optional Switches
Optional switches such as pressure, temperature, flow, etc. supplied by Ingersoll Rand but mounted by the
customer must be connected to the control panel. Information on how to wire these devices to the control panel is
shown on the Electrical Schematic.
Lubrication
NOTICE
The initial fill of lubricant for the Air compressor should be installed under the supervision of an
authorized Ingersoll Rand Technical representative.
Cleanliness of the lubrication system is of vital importance to the Centac air compressor. The system is flushed
and fully tested at the factory. If for any reason the oil system has been tampered with, then the following
procedure must be followed under the supervision of an authorized Ingersoll Rand Technical representative.
Piping Flush
1. Remove the sump access cover. Thoroughly clean the sump of any shipping oil and dry with lint free
rags.
2. Fill with recommended oil to the proper level and replace sump access cover.
3. Disconnect the oil piping at the entrance to the gear casing and use a flexible oil line to route the oil to
the sump in the baseplate.
4. Circulate the oil for a minimum of one hour using the prelube pump. Optimum flushing temperature is
38°C (100°F).
5. Tap any welded piping with a plastic or lead hammer during oil circulation to dislodge any foreign
material lodged at the welded joints.
6. Change position of the transfer valve at 15 minute intervals on systems having dual oil filters and/or
coolers.
7. Shut off the prelube pump.
WARNING
Hot oil can cause serious injury to personnel. Precaution must be taken to prevent contact with hot oil.
8. Drain the oil filter and inspect the element(s). Continue with one of the following:
• If foreign material is found in the filter housing or element, replace the oil filter and repeat step 4
through 8 until filter housing and element are clean upon inspection.
• If no foreign material is found, go to step 9.
9. Replace the oil filter element(s) and inspect the housing for cleanliness. Continue with Casing Flush.
Casing Flush
1. Reconnect lube piping to the gear casing.
2. Apply instrument quality air to the seals (6 PSIG [41 kPa] minimum).
3. Restart prelube pump and circulate oil for one hour.
4. Tap any welded piping with a plastic or lead hammer during oil circulation to dislodge any foreign
material lodged at welded joints.
5. Change position of the transfer valve at 15 minute intervals on systems having dual oil filters and/or
coolers.
6. Shut off the prelube pump.
7. Drain oil filter and inspect the element(s). Continue with one of the following:
• If foreign material is found in the filter housing or element, replace the oil filter and repeat step 3
through 7 until filter housing and element are clean upon inspection.
• If no foreign material is found, go to step 8.
8. Replace the oil filter element(s) and inspect the housing for cleanliness.
9. Fill sump to the proper level with recommended oil.
10. Replace sump access cover and secure.
Recommended Lubricant
Ingersoll Rand offers Techtrol Gold III, a synthetic lubricant specifically formulated for centrifugal compressors. If
Techtrol Gold III is not used, lubrication for the compressor system should be a synthetic lubricant. The lubricant
must have unusual oxidation stability and contain defoaming inhibitors and be free of inorganic acids or alkali.
There must be no tendency toward permanent emulsification and a minimum tendency to oxidize or form sludge
when agitated at operating temperatures when mixed with air and water.
CAUTION
Some lubrication mixtures are incompatible with each other and result in the formation of varnishes,
shellacs or lacquers which may be insoluble. Such deposits may cause serious trouble, including
clogging of the oil filter. Avoid mixing lubricants of the same type, but of different brands. A brand
change is best made at the time of a complete lubrication change.
CAUTION
Lubricant obtained by the user for operation of this equipment must comply with the following
specification and perform satisfactorily in the compressor. The Ingersoll Rand Company assumes no
responsibility for damages caused by non-compliance to this specification within the period of its
standard equipment guarantee or thereafter. On subsequent purchases of lubricant for use with this
equipment, the user is cautioned to be on the alert for any changes in the lubricant that may deviate from
this specification thereby causing equipment damage.
Physical and Chemical Requirements for Techtrol Gold III Coolant:
Property ASTM Test Method Limits

Physical:
ISO Viscosity Grade D2422 32
Viscosity Index D2270 139
Viscosity, cSt (SUS)
@ 0F/-17.8C D445 895 (4195)
@100F/37.8C D445 30 (142)
@104F/40C D445 28 (133)
@210F/98.9C D445 5.6 (45)
@212F/100C D445 5.5(44)
Pour point, F (C) D97-87 -40 (-40)
Flash Point, COC F (C) D92 450 (232)
Flash Point, PMCC F (C) D93-85 390 (199)
Chemical: (a)
Total acid number, mg KOH/g, max. D664 0.1
pH D664 8
Density (Grams per cc @25 C D941 0.988
Specific Gravity D941 0.99
Copper Strip Corrosion, 3 hrs. @ 212F/100C D130 1
Ferrous Metal Corrosion (Rust Test) D665A Pass
Foam Tendency (Sequence I,II,III) D892 0 (Nil)
NOTICE
Failure to meet this specification may result in damage to internal compressor components.
The pour point specification must be met unless there is a means available for heating the oil when used
in low temperature areas.
Ingersoll Rand does not endorse any other trade name product or any individual oil company.
Reservoir Capacities
Model Number Sump Capacity Sump Capacity Total Oil System
(Gallons) (Liters) Capacity (gal/lit)
C1000 55 208 60 gal / 227 liter
C1000 (option) 165 625 170 gal / 644 liter
NOTICE
The above listed values are for standard models and do not apply to API style sumps.
Total oil system capacities account for sump oil capacity plus oil piping.
The compressor is furnished with container(s) of oil sufficient for one fill.
Standard Oil Cooler and Filter Data

Lube Oil Cooler
Water side design pressure 150 PSIG 1034 kPa
Shell side design pressure 150 PSIG 1034 kPa
Lube Oil Filter

Single or Dual Element 10 Micron
Recommended Oil Temperatures

Minimum Oil Temperature for:
Starting 95°F 35°C
Operating Bearing Inlet Oil Temp. 100°F to 115°F 37.5°C to 46°C
Weights and Dimensions

Specific machine weights and dimensions will vary according to motor selected and any additional special
options purchased. The weights and dimensions provided are to be used for estimating purposes only. Refer to
the specific General Arrangement drawing for actual dimensions.
Length (in/mm): Width (in/mm): Height (in/mm): Weight (lb./Kg):
169.4 / 4302.3 86.3 / 2193.2 99.4 / 2523.9 32,500 / 14,741
Compressor Connections:
Inlet Air Connection: DIN 250 (10”)
Discharge Air Connection: DIN 150 (6”)
Bypass Air Connection: DIN 100 (4”)
Water Manifold Connections DIN 150 (6”)
(Inlet & Discharge):
Recommended Tools
The following list of standard mechanic’s tools is provided as a guide for installation of the compressor.
 Overhead crane for lifting the complete air compressor package

 Lifting Device (1/2 ton, or 500 kilos minimum) for lifting individual components
 Allen wrenches
 Feeler gauges
 Drive sockets with extensions
 Open end and box wrenches
 Adjustable wrenches
 Pipe wrenches
 Torque wrench (to 200 ft-lb or 300 Nm)
 Vise grips
 Channel locks
 Rubber or Lead hammer
 Dial indicator with magnetic base
 Digital Multimeter
 Machinist scale
 Transit Level
 Micrometer
Checklist Summary
All systems on the compressor should be checked prior to initial start-up. This check should be completed under
the direction of an Ingersoll Rand customer service representative.
The operational checklist can be found in the Operator Manual.
Check off each section before the initial start-up.
 The following are inspected for corrosion and cleanliness prior to start-up:
 Oil Reservoir
 Inlet Air Filter
 Inlet Air Piping
 Discharge Piping
 Bypass Piping
 Water Piping
 Check inlet air filter location and installation.
 Check the following on the inlet air piping:
 Material
 Minimum size
 Distance to first elbow (minimum of 4 pipe diameters)
 Facilities for moisture removal on any horizontal run of pipe
 Piping supports
 Manometer or differential pressure gages on inlet air filter
 Check the following on the discharge piping:
 Minimum size
 Distance to first elbow (minimum of 3 pipe diameters)
 Piping supports
 Safety valve (located between compressor discharge and check valve)
 Block valve
 Check the following on the bypass piping:
 Minimum size
 Distance to first elbow (minimum of 8 pipe diameters from bypass valve)
 Piping supports
 Location of silencer
 Check the following on the controlled air piping:
 Material
 Minimum size
 Attached to control panel at bulkhead fitting "CA"
 Attached to discharge air piping a minimum of 10 pipe diameters from check valve
 Check the following on the instrument air piping:
 Material
 Minimum size
 Attached to control panel at bulkhead fitting "IA"
 Attached to dry, clean air source, 60-120 PSIG (414-827 kPa) at 10 SCFM
(0.33 m3m) per stage minimum
 Absolute air filter (0.01 micron)
 Shut-off valve
 Check the following on the water piping:
 Minimum size
 Attachment to compressor
 Attachment to oil cooler
 Maximum of 150 PSIG (1034 kPa) water pressure
 Minimum of 35 PSIG (241 kPa) water pressure
 Differential pressure between inlet and outlet flanges on air coolers is normally 12 PSIG (15 PSIG
maximum) [83 kPa - 103 kPa maximum]
 Check for water leaks (leave condensate trap bypass valves open)
 Throttle valves at outlets (optional)
 Block valve on inlet
 Bonnet vents
 Check piping on condensate traps (piped to open drain).
 Check compressor lubricant, motor lubricant, & coupling grease for conformance to specifications.
 Fill oil reservoir to "Normal" level.
 Check anchor bolts and grouting.
 Check unit level.
 Check electrical power supply to unit.
 Check all control panel connections per applicable schematics.
 Manually rotate compressor and driver shafts, checking for free, uncoupled, rotation with prelube
pump running and seal air ‘on’.
 Check driver per manufacturer's instructions found in the individual unit's Operation Manual.
 Check driver electrical connections.
 Check direction of rotation and magnetic center of main drive on motor driven units prior to coupling to
compressor.
 Align driver to compressor.
 Install coupling spacer and lubricate coupling per manufacturer's instructions.
 Check rotation of prelube pump (three phase only).
 Check clearances on thrust bearings. Disregard if the access covers are wire sealed.
 Check lubrication system for oil leaks.
 Check operation and calibration of the inlet and bypass valves per the Operation Manual.
Customer Assistance
Ingersoll Rand is committed to serving you. We are strategically located to serve your needs. When you need
support for your product, contact your local Ingersoll Rand representative or call the factory direct. See
ingersollrandproducts.com for sales and service contact information.
U.S.: 800-247-8640
Europe: 00 39 02 950561
China: 800-820-2128
Notices and Disclaimers

Copyright Notice
Copyright 2010 Ingersoll Rand Company.
Proprietary Notices
CENTAC is a registered trademark of Ingersoll Rand Company.
This manual contains confidential and trade secret information owned by Ingersoll Rand Company (hereinafter
referred to as “Proprietary Matter”). In consideration of the disclosure of the Proprietary Matter herein to the
authorized recipient hereof, the recipient shall treat the Proprietary Matter as secret and confidential; shall not
disclose or give such Proprietary Matter to third parties without the express written authorization of Ingersoll
Rand; shall not use the Proprietary Matter except to the extent necessary to use or service the equipment
disclosed herein; and shall disclose such Proprietary Matter only to those of its employees whose use or
knowledge of the Proprietary Matter is necessary. This manual shall be returned upon request by Ingersoll Rand
Company. The unauthorized use of this manual may be punishable by law.
Disclaimers
 This manual and the contents thereof are provided “as is” and without any implied warranties.
 The information in this manual does not relieve operating and maintenance personnel of the
responsibility of exercising normal good judgment in operation and care of the compressor and its
components.
 The company accepts no responsibility for errors in translation of this manual from the original English
version.

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CENTAC ®

C1000 Planning & Installation Manual

Electrical Connections___________________________________________________________ 22

About This Manual

 General Arrangement Drawing

General Workplace Safety

Documentation, Decals & Tags

Personal Protective Equipment & Attire

Handling & Transporting

Installation Materials & Components

Explanation of Safety Signal Words

Indicates a potentially hazardous situation which, if not avoided, could result in

Indicates a potentially hazardous situation which, if not avoided, may result in

Indicates information or a company policy that relates directly or indirectly to

Do not attempt to lift the

Do not breathe the compressed

Instruction book location. Hot surface.

Do not remove the operating and

Oil fill. Lifting point.

Direction of rotation of the

Do not stand on any service

Figure 1 — Lifting Diagram for Standard Unit

 It has been delivered to the job site and is awaiting installation.

Leveling wedges Leveling shims

Figure 2 — Wedge and shim placement

 Dead weight of the piping itself

 Providing adequate support for all parts of the piping system.

Inlet Air Piping

Inlet Air Filter

Remote Inlet Air Filter

 A 0.3 micron inlet air filter

 A chemical type filter

Work platform 8 ft. (2.4 M) min.

Max p 0.3 psi (2.1 kPa[a])

Inlet air temp Removable

Long radius elbow

Figure 3 — Inlet Air Piping – Air Filter

Remote Bypass Air Silencer/Piping

Alt. side wall discharge

Figure 4 — Model Bypass Pipe

Local Bypass Air Silencer/Piping (Optional)

Discharge Air Piping

“CA” tap in. To be located a minimum

Discharge pressure Non-rusting control air line.

Long radius elbow.

Figure 5 — Model Discharge Pipe

Discharge Air Piping for Multi-Compressor Installation

Figure 6 — Centrifugal and Positive Displacement Piping Arrangement

Control Air Piping

Figure 7 — Control Panel Connections

Instrument Air Piping

Water System Piping

Cooling Water Piping

Cooling Water Specification

 Total hardness expressed as CaCO3 should be less than 100 PPM.

 Temperature differences within a system.

Air Cooler Vent Lines

Figure 8 — Visual indicator of water flow through vent lines

Condensate Drain Piping