Related Manuals for Gardner Denver ELECTRA-SAVER EAU PD - 200 HP
Summary of Contents for Gardner Denver ELECTRA-SAVER EAU PD - 200 HP
- Page 1 13–10–612 GARDNER DENVER 1st Edition August, 1994 ELECTRA–SAVER STATIONARY SCREW COMPRESSOR With AUTO SENTRY –ES CONTROLLER MODELS EAU_PD – 200 HP EAU_QD – 250 HP EAU_RD – 300 HP OPERATING AND SERVICE MANUAL...
- Page 2 Denver or Joy air compressor with these services: viding fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Factory: Gardner Denver Machinery Inc.
- Page 3 FOREWARD Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine the owner must exercise care in its operation and main- tenance. This book is written to give the operator and maintenance department essential information for day–to–day operation, maintenance and adjustment.
- Page 4 TABLE OF CONTENTS GENERAL INFORMATION ........... . SECTION 1 INSTALLATION .
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Page 5: Table Of Contents
INDEX Acoustic Enclosure ......Compression Principle ..... . Air Receiver, Auxiliary . - Page 6 INDEX Gauge, Oil Level ......Controls and Instruments,General ... Gauges and Displays .
- Page 7 INDEX MAINTENANCE SCHEDULE, SECTION 8 . . . Oil Cooler Pressure Differential (Water–Cooled Heat Exchanger) ..... Maintenance Schedule ..... Oil Cooler Temperature Differential (Air–Cooled Minimum Discharge Pressure/Check Valve .
- Page 8 INDEX High Pressure ......Oil Separator ......High Temperature .
- Page 9 INDEX Water Flow Control for Heat Exchanger ..Water Piping, Water–Cooled Heat Exchanger ..... . . Water Shutoff, Water–Cooled Heat Exchanger .
- Page 10 LIST OF ILLUSTRATIONS Figure 1–1 Compression Cycle ............Figure 1–2 Package –...
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Page 11: Air Flow
SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSION CYCLE COMPRESSOR – The Gardner Denver Electra– mixture trapped in the interlobe cavity by the rotors Saver compressor is a single–stage, positive dis- passes the discharge port and is released to the oil res- placement rotary machine using meshing helical rotors ervoir (C). -
Page 12: Figure 1-2 Package - Unit With Water Cooled Aftercooler
FIGURE 1–2 – PACKAGE – UNIT WITH WATER COOLED AFTERCOOLER FIGURE 1–3 – PACKAGE – UNIT WITH WATER COOLED AFTERCOOLER 13–10–612 Page 2... -
Page 13: Figure 1-4 Starter Box
FIGURE 1–4 – STARTER BOX FIGURE 1–5 – PACKAGE – CONTROLLER AND STARTERS 13–10–612 Page 3... - Page 14 SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.
- Page 15 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
- Page 16 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–10–612 Page 6...
- Page 17 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–10–612 Page 7...
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Page 18: Figure 2-1 Typical Compressor Room
SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- If the air–cooled oil cooler module is to be installed at age that may have been incurred during transit. Report a location remote from the compressor unit, be sure any damage or missing parts as soon as possible. -
Page 19: Acoustic Enclosure
unit near level. Temporary installation may be made at a maximum of 10 angle lengthwise or 30 sidewise. Mounting bolts are not normally required. However, installation conditions such as piping rigidity, angle of The low demand mode switch cannot tilt, or danger of shifting from outside vibrations or mov- be used with remote overhead oil ing vehicles may require the use of mounting bolts to coolers. -
Page 20: Aftercooler
The moisture separator is furnished by port clamps or hangers and position them to re- Gardner Denver but must be mounted by the customer lieve any piping stress at the oil cooler inlet and between the aftercooler and the auxiliary air receiver outlet ports. -
Page 21: Water-Cooled Machine
(32 F, 0 C). This will Use only Gardner Denver AEON 9000 SP Lubri- eliminate many of the problems associated with operat- cating Coolant. -
Page 22: Control Piping
FIGURE 2–5 – INSTALLATION FOR COLD WEATHER OPERATION Monitor the unit carefully during start–up and op- Some means of providing heat to the oil reservoir eration to be sure it is functioning normally. and cooler during shutdown should be provided. There are various methods to accomplish this, but Use NEMA 4 enclosure for electrical devices. -
Page 23: Figure 2-7 Heat Exchanger (Oil Cooler) Approximate Water Flow
AFTERCOOLER Approx. Water Temperature to Heat Exchanger Water Pressure Rated Maximum Drop @ Pressure Water Maximum Flow Size PSIG 60 F. 70 F. 80 F. 90 F. Flow (PSI) 200 HP 21.0 250 HP 23.0 300 HP ––– 25.0 The maximum water flow shown is that allowable through the heat exchanger. FIGURE 2–7 –... -
Page 24: Aftercooler - Heat Exchanger Water Piping
mum pressure of 40 PSIG; maximum allowable water The water control valve MUST be used to maintain dis- pressure is 150 PSIG. The water flow rates shown in charge temperatures approximately 10 F. over the FIGURE 2–7, Page 13, are approximate and a guide to dew point for expected ambient (FIGURE 5–8, page sizing piping, cooling tower and other water system 41). - Page 25 MOTOR LUBRICATION – Long time satisfactory op- Leave the relief plug temporarily off. Reconnect eration of an electric motor depends in large measure the unit and run for about 20 minutes to expel the on the bearings and timely lubrication. The following excess grease.
- Page 26 ADD OIL range. Do not mix different types of ter”, for complete servicing instructions. Be sure oils. The unit is shipped filled with Gardner Denver the inlet line, if used, is tight and clean. AEON 4000 lubricating coolant which is suitable Coupling –...
- Page 27 A proper sequencing installation requires two or more a wall jack. The only item required to make the system Gardner Denver rotary air compressors complete with functional is a standard telephone cable identical to ”AUTO SENTRY–ES” controllers, piped into a com- cables that connect nearly every telephone to its wall mon air system, interconnected as described above.
- Page 28 vacant; the other has a short pigtail plugged into it. To ing a master, they are also capable of delivering air at interconnect two compressors, plug the cable into the a pressure determined by the above formula. vacant jack on each controller. For installations of more To insure that two or more machines do not simulta- than two units, the pigtail plug must be disconnected on neously decrement their rotation numbers and simulta-...
- Page 29 tion setpoint (PSET for short) is [SET PRESSURE – numbers were greater than the missing number. Like- 3(rotation number – 1)]. Thus in the above example, the wise, if for whatever reason, the master compressor first lag compressor (rotation #2) has a PSET of 97 fails to carry out its role, all lag compressors begin PSI;...
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Page 30: Figure 4-1 Schematic Tubing Diagram
SECTION 4 – EAU UNITS CONTROLS & INSTRUMENTS GENERAL – The Gardner Denver Electra–Saver PROTECTIVE DEVICES, ADVISORIES AND SHUT- compressor’s controls and motor are prewired for the DOWNS – The ”AUTO SENTRY–ES” will shut down voltage and horsepower specified at the time of the or- the unit following any fault detected in the following de- der. -
Page 31: Figure 4-2 Inlet Valve
High Temperature – The compressor is protected Separator Differential Pressure – The separator dif- from high discharge and separator temperature by two ferential pressure is continually monitored by the ”Auto independent thermistor probes. One probe is located Sentry–ES.” At a differential pressure of approximately in the discharge housing to sense compressor dis- 15 psi, the unit will be shut down. -
Page 32: Blowdown Valve
When the relief valve opens, a stream of high velocity air is released, result- ing in a high noise level and possible discharge of accumulated dirt or oth- er debris. Always wear eye and ear protection and stand clear of the dis- charge port when testing the relief valve to prevent injury. -
Page 33: Actuator, Turn Valve
Discharge Compressor Manifold Delivery Inlet Valve Turn Valve Pressure Full Capacity Open Closed 70% Capacity Open 50% Open 40% Capacity Open Full Open 30% Capacity Closing Full Open 20% Capacity Closing Full Open 0% Capacity Closed Full Open CONTROL COMPONENTS –... -
Page 34: Minimum Discharge Pressure/Check Valve
213ECM797 (Ref. Drawing) FIGURE 4–5 – TURN VALVE ders to move the rack and rotate the valve. Located on Minimum Discharge Pressure/Check Valve the end of the cylinders are adjusting screws which limit (FIGURE 1–5, page 3, and FIGURE 4–6, and the travel of the actuator. -
Page 35: Air Filter Vacuum
Repair kits are available from your servicing unit. local authorized Gardner Denver Distributor. System Pressure Transducer – This transducer is connected after the minimum pressure valve and dis- Control Transformer – This changes the incoming charge check valve. -
Page 36: Automatic Mode Operation
In any mode, the compressor will start only if reservoir main in this state until demand is again indicated by a pressure is below 5 psig. The display will indicate if the drop in pressure. control is waiting for blowdown. The controls will keep Sequence Mode Operation –... -
Page 37: Programming And Setup Instructions
Following service, put the enable switch in the down, ”+” position. Restore power to the unit. The display will read: Between each key it is necessary to SHUTDOWN POWER FAILURE. press the ”ENTER” key to restore the Press the STOP/RESET. The display will show new value and advance to the next the ready mode in the lower right hand corner. - Page 38 through eight This will be factory set at ”1”. Each ”AUTO SENTRY–ES” in a sequenced system must have a unique number here. The sequence mode will not function if two or more compressors This concludes operator accessible have the same UNIT NUMBER. Most efficient ma- adjustments.
- Page 39 of 8000 hours. 8000 hours is the maximum set- LARGE if estimated volume is greater than 1.0 ting, and is the proper change interval for AEON gallon per CFM. 9000 SP synthetic oil. See FIGURE 5–3, Section 5, page 37 for proper setting for AEON lubricants. 16.
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Page 40: Figure 4-8 Control Schematic - Compressor At Full Load
214ECM797 (Ref. Drawing) FIGURE 4–8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD... -
Page 41: Figure 4-9 Control Schematic - Compressor Fully Loaded - Low Demand Mode
216ECM797 (Ref. Drawing) FIGURE 4–9 – CONTROL SCHEMATIC – COMPRESSOR FULLY LOADED – LOW DEMAND MODE... -
Page 42: Figure 4-10 Wiring Diagram
212EAP546 (Ref. Drawing) FIGURE 4–10 – WIRING DIAGRAM... -
Page 43: Figure 4-11 Auto Sentry-Es Controller Display
FIGURE 4–11 – AUTO SENTRY–ES CONTROLLER DISPLAY... -
Page 44: Change Procedure, Lubricant
Change to a new filter and separator. leum base lubricant formulated and containing addi- Fill the system with a full charge of the new lubri- tives for use in Gardner Denver compressors. cant. Replace the drain plug before restoring power. -
Page 45: Figure 5-1 Flow Diagram - Air/Oil System
215EAU797 (Ref. Drawing) FIGURE 5–1 – FLOW DIAGRAM – AIR/OIL SYSTEM... -
Page 46: Addition Of Oil Between Changes
Find and correct the malfunction before resuming operation. Air/oil under pressure will cause severe personal injury or death. Shut All materials used in Gardner Denver down compressor, relieve system of compressor units are compatible with all pressure, disconnect, tag and AEON 9000 SP Lubricating Coolant. -
Page 47: Cleaning And Draining Oil System
RUN range or approximately 3.5 Gardner Denver offers a free oil analysis program with inches below the centerline of the oil reservoir. the AEON lubricants and we recommend a sample be sent in at 1000 hours on a new unit. -
Page 48: Compressor Oil Filter
If the unit is elevated so that the oil reservoir drain can be used, empty the oil reservoir through the drain valve to a suitable container or sump. If the drained oil and/or the oil filter element are contaminated with dirt, flush the entire system: reservoir, oil cooler, mixing valve and lines. -
Page 49: Compressor Oil Cooler (Radiator Type)
Refer to FIGURE 5–4, page 38, for the following instructions: To remove cannister (3) rotate tie bolt (10) coun- terclockwise until the cannister is free of head as- sembly (1). Remove the element (6) from the cannister. Re- move indicator assembly (5) from the element by inserting a screwdriver between the indicator as- sembly and element and carefully prying down- ward. -
Page 50: Compressor Oil Cooler - Water Cooled Heat Exchanger
neering for approval and for recommending the pipe size. A special control group will be mounted on the package at the factory. This group controls the oil stop valve as well as not allowing the machine to run un- loaded. Remote mounted elevated coolers have a maximum pipe length of 30 feet (each way) and a maximum height of... -
Page 51: Figure 5-7 Water Control Valve
FIGURE 5–7 – WATER CONTROL VALVE FIGURE 5–8 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE (100% RELATIVE HUMIDITY) gauge. At normal operating air service pressure (65 to growth of microorganisms. The normal maintenance 150 PSIG) with unit warm, a pressure drop of 2 to 25 program for the unit should include periodic cleaning on PSI can be expected between the oil inlet and the oil the tube side (water side) of the heat exchanger to re-... -
Page 52: Compressor Oil Separator
an index line for use with the index scale 0 to 8 in obtain- moisture in the oil, or oil return line malfunction. If oil ing a desired setting. carryover occurs, inspect the separators only after it is determined that the oil level is not too high, the oil is not These valves must be handled with care and proper foaming excessively, the oil return line from the dis- tools and techniques must be used when working on... -
Page 53: Removal For Inspection
and completely withdraw the tubing through the fitting. Disconnect all other tubing from the discharge manifold. Disconnect the discharge manifold pipe union. Remove screws holding the top plate to the oil res- ervoir. Lift the top plate from the oil reservoir. Lift the separator from the oil reservoir. -
Page 54: Figure 5-10 Discharge Temperature Chart
Oil Cooler Oil Pressure Differential (Air–Cooled Ambient Temp. ( F.) Radiator) – 2 to 25 PSI (65 to 150 PSIG Receiver Pres- sure) – Check at the fitting in the inlet and outlet lines 200 HP Discharge of the oil cooler. 250 HP Temperature 205*... -
Page 55: Air Filter
Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water. Im- proper cleaning may damage the ele- Use only genuine Gardner Denver air ment. filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. -
Page 56: Air Filter, Heavy Duty 200 Hp Units
Higher than normal current use by the motor or loss of compressor delivery may indicate a need for servicing the filter element. Use only genuine Gardner Denver air To Service: filter elements on Gardner Denver Loosen the retaining band clamp and remove the compressor units. -
Page 57: And 300 Hp Units
FIGURE 6–2 – HEAVY–DUTY FILTER, 250 & 300 HP Inlet Screen and Tube – Inspect the inlet screen and To service, stop the unit. Remove and clean the dust tube for dirt accumulation each time the filter element cup as previously described under ”Dust Cup.” Inspect is serviced. -
Page 58: Filter Element Life
When assembling the element in the body, be sure the wing nut is tight and the clamp on the filter holds the cover firmly against the gasket. Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Do not oil this element. -
Page 59: Figure 7-1 Installation Of Coupling Cushions
SECTION 7 COUPLING FIGURE 7–1 – INSTALLATION OF COUPLING CUSHIONS Working through coverplate opening, center cou- pling over the gap between the shafts, maintaining the gap as shown in FIGURE 7–1 between the ends of the jaws on one coupling body and the Rotating machinery cause... - Page 60 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency of Every 125 Hours Operation service. The ”CHANGE AIR FILTER” LED will flash to Check for dirt accumulation on oil/aftercooler core signal that the air filter requires servicing or changing. faces and the cooling fan.
- Page 61 SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate heaters tripped. cause of overload. Pressure in reservoir. Inspect blowdown valve. Read error message on Replace switch.
- Page 62 SYMPTOM POSSIBLE CAUSE REMEDY Compressor cycles from Insufficient receiver capacity. Increase receiver size. load to unload excessively. Restriction in control Inspect and clean tubing. control tubing. Compressor is low on Restricted air filter. Clean or replace filter. delivery and pressure. Sticking inlet valve.
- Page 63 Ruptured oil separator Replace element. element. Loose assembly. Tighten all fittings and gaskets. Foam caused by use of Use Gardner Denver incorrect oil. AEON 4000 or 9000 SP Lubricating Coolant. Inoperative minimum Clean out or replace pressure valve causing low valve.
- Page 64 Probable cause –– plugged or dirty cooler, high ambient conditions, or blown fuses on fan motor. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units.
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