Related Manuals for Gardner Denver ELECTRA-SAVER EAYQ E
Summary of Contents for Gardner Denver ELECTRA-SAVER EAYQ E
- Page 1 13–10–613 SP GARDNER DENVER 2nd Edition December, 1995 ELECTRA–SAVER STATIONARY BASE–MOUNTED COMPRESSOR WITH OPTIONAL ES+ CONTROLLER MODELS EAYQ_E EAYS_E OPERATING AND SERVICE MANUAL...
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Page 2: Remanufactured Air Ends
They are ready to respond and assist you by pro- Your authorized distributor can support your Gardner 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: Foreword
FOREWORD 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
TABLE OF CONTENTS Remanufactured Air Ends ................Foreword . -
Page 5: Index
INDEX Actuator, Turn Valve ..... . . Cold Weather Operation, Installation for ..Addition of Oil Between Changes . - Page 6 INDEX Low Oil Pressure Shutdown ....Electric Motor Grease Recommendations ..Lubricant, Recommended ....Electric Motor Regreasing Interval .
- Page 7 INDEX Safety Precautions ..... . . 4–5 Oil Cooler Water Pressure Differential ..Schematics, Control ..... . . Oil Inlet Pressure .
- Page 8 INDEX Shuttle Valve ......TROUBLE SHOOTING, SECTION 9 ..TROUBLE SHOOTING CONTROLS, SECTION Solenoid Valves IVC and IVO .
- Page 9 LIST OF ILLUSTRATIONS Figure # Description Page Figure 1–1 Compression Cycle ............Figure 1–2 View of Water Cooled Unit with Aftercooler (less enclosure) –...
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Page 10: Section 1, General Information
SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSION CYCLE COMPRESSOR – The Gardner Denver Electra–Saver mixture trapped in the interlobe cavity by the rotors compressor is a single stage, positive displacement passes the discharge port and is released to the oil res- rotary machine using meshing helical rotors to effect ervoir (C). - Page 11 208EAY797 (Ref. Drawing) FIGURE 1–2 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – MOTOR SIDE 208EAY797 (Ref. Drawing) FIGURE 1–3 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) – MOTOR END 13–10–613 SP Page 2...
- Page 12 208EAY797 (Ref. Drawing) FIGURE 1–4 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) COMPRESSOR – RESERVOIR END 208EAY797 (Ref. Drawing) FIGURE 1–5 – VIEW OF WATER COOLED UNIT WITH AFTERCOOLER (LESS ENCLOSURE) RESERVOIR SIDE 13–10–613 SP Page 3...
- Page 13 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 14 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 15 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–10–613 SP Page 6...
- Page 16 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–10–613 SP Page 7...
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Page 17: Section 2, Installation
SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- cases it may be necessary to install the air filter at some age that may have been incurred during transit. Report distance from the compressor to obtain proper air sup- any damage or missing parts as soon as possible. - Page 18 PIPING SCHEMATIC OF COOLER PIPING SCHEMATIC OF COOLER WITH SCREWED CONNECTIONS. WITH FLANGED CONNECTIONS. FIGURE 2–3 – PIPING SCHEMATIC VENTILATION – The unit, whether air– or water– ACOUSTIC ENCLOSURE – The Electra–Saver unit is cooled, requires sufficient air flow, FIGURE 2–2, for furnished with an acoustic enclosure over the compres- electric motor cooling.
- Page 19 FIGURE 2–4 – PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER ers, and valves to be used in the pipe run. A dimensional sketch of the proposed piping sys- tem showing location of the compressor unit, oil The machine cannot be run blown cooler, pipe, and fittings illustrating design in- down with remote overhead oil cool- formation included in numbers 3 through 6 above.
- Page 20 The moisture separator is furnished by Set the unit level on a firm, solid foundation. The Gardner Denver but must be mounted by the customer larger oil cooler models have lifting holes to facili- between the aftercooler and the auxiliary air receiver tate unit hoisting.
- Page 21 A means of draining condensate will need to be pro- Use only Gardner Denver AEON 9000 SP lu- vided for.
- Page 22 HEAT EXCHANGER Water Temperature to Heat Exchanger Approximate Rated Gallons/minute Maximum Water Pressure Pressure Water Flow Drop @ Maximum Size PSIG 60 F. 70 F. 80 F. 90 F. Flow (PSI) 350 HP 21.0 400 HP 21.0 500 HP 17.0 The maximum water flow shown is allowable through the heat exchanger.
- Page 23 nections are located in the unit base flange on the left side of the unit. When an aftercooler is piped in series with the oil cooler, the maximum allowable flow rate through the It is mandatory that any water cooled oil/aftercooler system is the max- unit be installed in a shelter heated to imum allowed by the aftercooler.
- Page 24 GROUNDING – Equipment must be grounded in ac- Remove the relief plug and free hole of hardened cordance with Section 250–95 of the National Electrical grease. Code. Wipe lubrication fitting clean and add grease with a hand–operated grease gun. The amount and type of grease added is very im- portant.
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Page 25: Section 3, Starting & Operating Procedures
Refer to Section 6, “Air Fil- red “ADD OIL” range. Do not mix different type ter,” page 51, for complete servicing instructions. oils. The unit is shipped filled with Gardner Denver Be sure the inlet line, if used, is tight and clean. AEON... - Page 26 System Pressure – Set the controls to the de- Check all screws and latches for tightness. Be sired load pressure. DO NOT EXCEED THE sure doors are closed and latched. MAXIMUM OPERATING PRESSURE ON THE STARTING THE UNIT – OBSERVE UNIT COLD OR COMPRESSOR NAMEPLATE.
- Page 27 SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION – The Gardner Denver will prevent loading while the key is held down. When rotary screw compressor is prewired with all controls, the key is released, the control will resume its normal motor, and starter for the voltage and horsepower at operation as required.
- Page 28 Low Demand Mode Operation – The low demand plications with long unloaded periods (e.g. idle shifts or mode reduces power consumption by relieving pres- weekends) and adequate storage to allow the com- sure in the reservoir during unloaded operation. This pressor to be stopped for periods of light demands.
- Page 29 Communication between controllers is achieved by in- of the shutdown. A red indicator on the diagram indi- terconnection of a communications cable to circuit cates the area needing service. board connectors. A “unit number” must be assigned to each unit in this mode, but the display will indicate the SERVICE ADVISORIES unit’s actual operating ranking.
- Page 30 ervoir / separator temperature is also monitored, and clude: high vibration, phase relay, low voltage relay, will provide high temp shutdowns. The location of the and water press. temperature fault will be displayed. Thermistor probes Amp Sensor Failure – The optional current sensor are also checked for open or shorted circuits, and the used with the ES+ controller is used for operational tun- display will indicate the location of the defective probe.
- Page 31 FIGURE 4–2 – FLOW CHART FOR SET–UP PROGRAMMING...
- Page 32 Note: Configuration adjustments are normally re- dumping of compressed air when loading is likely quired only at the time of assembly or after parts have to occur in a short time. been replaced. Unit setup adjustments are normally In the top line, “AUTO TIME” is displayed. The required only at the time of unit installation.
- Page 33 terval (see UNIT SETUP) if service was per- In the top line, “TRANSFER INTERVAL” is dis- formed early. Press again to change back to re- played. The bottom line will indicate a number of maining time. When the desired value is shown, hours in the range of 1 to 5000.
- Page 34 tem pressure is, in fact, zero psig. Remove the Select “WATER COOLED” for water cooled units pressure line to the system pressure transducer. or any unit with a remote cooler. This will run the Pressing [ENTER] will now cause the “AUTO fan whenever the compressor motor runs.
- Page 35 to 0.2 seconds is normally adequate for factory– operating voltage, in particular, can cause high amp furnished full–voltage starters; wye–delta or re- draw. This will heat the motor beyond its design, and mote starters may require a little more time. Set will normally trip the overload relay to prevent motor back to zero to proceed to the next step.
- Page 36 control system will operate only as many compressors to the entire storage volume of a physical receiver and as are needed to supply the CFM demand of the plant, the volume of the air distribution throughout the plant. and to maintain the compressor system pressure be- Modulating systems work best when the receiver is at tween the SET and RESET pressures programmed least one gallon for the rated CFM of a member com-...
- Page 37 Program all members of the system, as described in During this procedure, the system is not deprived of air. the programming procedure on previous pages. All ad- This is due to one of the outstanding features of the justments should be identical for each member, except “AUTO SENTRY–ES+”...
- Page 38 SEQUENCED SYSTEM CHECKOUT system storage (normally the air storage receiver). The “AUTO SENTRY–ES+” sequencing system is de- One of the best indicators of the stability of the system signed to tolerate minor variations. The “AUTO is to compare the local system pressure of a running SENTRY–ES+”...
- Page 39 202EAY797 (Ref. Drawing) FIGURE 4–3 – SCHEMATIC TUBING DIAGRAM the message “REMOTE HALT” to indicate that it is SHUTDOWN. The unit must be serviced and reset lo- waiting for the remote signal. cally. Alarm Relay – The ES+ controller is provided with an If the compressor was running in any mode when the alarm relay which may be connected to a remote contact was opened, and the remote response is pro-...
- Page 40 data to external monitoring systems. Data available in- clude all pressures and temperatures, and a reports of internal service data. This is accessible with a PC or PLC with an appropriate communications port. For protocol information, request drawing 201EAU1255. OTHER CONTROL DEVICES Besides the electronic controller noted above, the fol- lowing components are also used to control operation of the compressor unit.
- Page 41 The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver Machinery distributor. Inlet Valve (FIGURE 1–4, page 3, and FIGURE 4–6) – The Inlet valve restricts the inlet to control delivery and closes to unload the compressor.
- Page 42 of the two actuating cylinders to move the rack and ro- tate the valve. Located on the ends of the cylinders are adjusting screws which limit the travel of the actuator. The adjusting screw on the top adjusts the open posi- tion of the turn valve;...
- Page 43 FIGURE 4–9 – TURN VALVE ACTUATOR how the turn valve position is controlled during normal operation. Automatic restarting or electrical System Pressure Transducer – This transducer is connected after the minimum pressure valve. It con- shock can cause injury or death. verts the pressure in the plant air system into an electri- Open, tag and lockout main discon- cal signal for use by the “Auto Sentry–ES+”...
- Page 44 fer to the transformer label for connection prior to ener- The turn valve controls compressor delivery to match gizing. Two primary and one secondary fuse are pro- demands of 40% to 100% of the compressor’s maxi- vided. Refer to adjacent labeling for replacement mum capacity.
- Page 45 204EAY797 (Ref. Drawing) FIGURE 4–10 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD...
- Page 46 205EAY797 (Ref. Drawing) FIGURE 4–11 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – CONSTANT SPEED MODE...
- Page 47 206EAY797 (Ref. Drawing) FIGURE 4–12 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE...
- Page 48 202EAY546 (Ref. Drawing) FIGURE 4–13 – WIRING DIAGRAM...
- Page 49 The separated oil is re- AEON 4000 Lubricating Coolant is a superior petro- turned to the compressor and the air passes to the final leum base lubricant formulated and containing addi- discharge line. tives for use in Gardner Denver compressors. 13–10–613 SP Page 40...
- Page 50 Drain oil from air end and cooler while hot. – Break low point connections and drain oil from pipe runs. All materials used in Gardner Denver – Dump oil from the filter and reinstall used fil- compressor units are compatible with ter.
- Page 51 Material Safety Data Sheets (MSDS) are available for Approximate Qty. – Top all AEON lubricants from your authorized Gardner System Reservoir of ADD to Denver distributor or by calling 217–222–5400. Capacity Capacity** Centerline Size (Initial Fill) (Refill) of RUN COLD AMBIENT OPERATION – See “Installation for Cold Weather Operation,”...
- Page 52 drain the moisture and correct the condition causing the accumulation. See “Compressor Oil System Check,” page 50 and “Thermal Control (Thermostatic Mixing) Valve,” page 46. Compressor, air/oil reservoir, separa- tion chamber and all piping and tub- OIL CHANGE INTERVAL – Recommended oil change ing may be at high temperature during intervals based...
- Page 53 FILLING OIL RESERVOIR Element must be replaced every 1000 hours or sooner, or when top of the Air/oil under pressure will cause indicator on the filter is in the red severe personal injury or death. Shut CHANGE FILTER half of the window. down compressor, relieve system of Unit must be running and warmed up all pressure, disconnect, tag and...
- Page 54 (3) and rotate tee handle (9) clockwise until hand tight; do not exceed 20 foot–pound torque if tools are used. Reconnect starter to power source. If leakage appears around tee handle (9) remove snap ring (11) and remove tee handle (9) from head assembly (1).
- Page 55 cal connection to the main compressor unit. Connect- ing piping and wiring are furnished by the user. See “Installation”, Section 2, page 8. Do not obstruct the air flow to and from the oil cooler. Allow two (2) feet clearance on all sides of the oil cooler. See FIGURE 2–2, Section 2, page 8, for cooling air flow requirements.
- Page 56 FIGURE 5–7 – WATER CONTROL VALVE FIGURE 5–8 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE (100% RELATIVE HUMIDITY) the oil from the cooler to mix with oil from the bypass. Oil cooler malfunction may be traced by checking pres- After the unit is warmed up, the mixing valve maintains sure at oil inlet and outlet.
- Page 57 ter side) of the heat exchanger to remove deposits which enhance fouling and corrosion. Hex head zinc anodes are used in the return bonnet (opposite end to the water pipe connections) of heat ex- changers to provide internal water system corrosion protection.
- Page 58 is not foaming excessively, the oil return line from the Removal Of Oil Separator For Inspection Or Re- separator housing to the compressor cylinder is not placement: clogged or pinched off, the check valve in the oil return line is functioning properly, and there is not water or an oil/water emulsion in the oil.
- Page 59 13. Install original oil return by slipping tube through ture level of FIGURE 5–10. Small variations in specific the fitting at the discharge manifold flange until water flows or temperatures will not be noted in the dis- ferrule bottoms in the fitting. If a new fitting and charge temperature since the water control valve will return tube are used, slip the tube through the tend to hold a constant oil temperature.
- Page 60 Filter Element – Service the air filter element when the “CHANGE AIR FILTER” LED is illuminated. Clean ev- ery 50 to 150 operating hours depending on dust con- ditions. Use only genuine Gardner Denver air filter elements on Gardner Denver To service: compressor units. Genuine parts are...
- Page 61 – wipe clean with a clean dry cloth. Do not bend the edge of the cup by striking on a hard surface. When Use only genuine Gardner Denver air installing the dust cup, make sure the clamp is securely tightened to prevent leakage.
- Page 62 SECTION 7 COUPLING B76633X FIGURE 7–1 – INSTALLATION OF COUPLING – STYLE “A” FIGURE 7–2 – INSTALLATION OF COUPLING – STYLE “B” COUPLING – The motor and compressor are direct cushions and secure with cap screws. Rein- connected by a flexible coupling. Style “A” coupling has stall the cover plate.
- Page 63 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. If the “CHANGE AIR FILTER” message is Check for dirt accumulation on oil/aftercooler core displayed, air filter requires servicing or changing. See faces and the cooling fan.
- Page 64 SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
- Page 65 SYMPTOM POSSIBLE CAUSE REMEDY Compressor is low on 1. Restricted air filter. 1. Clean or replace filter. delivery and pressure. 2. Sticking inlet valve. 2. Inspect and clean inlet valve. 3. Unload pressure adjusted 3. Adjust the unload pressure. too low. See Section 4, page 33.
- Page 66 9. Check oil reservoir tempera– ture and if low, change thermal mixing valve element to higher temperature. 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. 13–10–613 SP...
- Page 67 SECTION 10 TROUBLE SHOOTING CONTROLS AUTO SENTRY ES+ CONTROLLER DISPLAY MODES The normal display indicates the package service pressure, the airend discharge, the total running hours, and one of the following operating modes. The green light will be on for any operating mode, whether the compressor is run- ning or not.
- Page 68 The compressor schematic area has red shutdown and yellow service advisory indicator lights. AIR FILTER yellow indicates that the filter needs to be changed DISCH THERM yellow indicates high temperature operation DISCH THERM red indicates a high temperature shutdown SEPARATOR yellow indicates the separator needs to be changed SEPARATOR red indicates a change separator shutdown...
- Page 69 SHUTDOWN TROUBLESHOOTING GUIDE All shutdowns are indicated on the keypad by the word “SHUTDOWN” on the top line of the display, and one of the following messages on the lower line of the display. The red indicator in the Status area will be steadily lit while the conditions exist, and will flash after the condition has been corrected.
- Page 70 SHUTDOWN TROUBLESHOOTING GUIDE (Continued) Message Action Needed HIGH DISCH TEMP This indicates that the controller has detected temperature in excess of the pro- grammed high temperature limit at the airend discharge. The most common cause for this is inadequate package cooling. Ensure proper air flow for air- cooled units, or adequate cooling water for water cooled units.
- Page 71 SHUTDOWN TROUBLESHOOTING GUIDE (Continued) Message Action Needed MAIN STARTER The controller has attempted to start the compressor, but did not receive a re- turn signal from the starter’s auxiliary contact. If the starter does not pick up when attempting to start, check that connector 9 of the controller is plugged in firmly, and check the starter coil.
- Page 72 CONTROLS TROUBLESHOOTING GUIDE The following are recommended service actions. Observe all instructions noted elsewhere in this manual. All electri- cal service is to be performed only by a qualified electrician. Symptom Recommended Action No display, Check incoming power to the compressor unit. Ensure that the disconnect is compressor stopped on and that fuses have not blown (or circuit beaker tripped).
- Page 73 CONTROLS TROUBLESHOOTING GUIDE (Continued) Symptom Recommended Action Low reservoir pressure The ES+ controller will maintain a minimum pressure in the oil reservoir while in CONSTANT mode in CONSTANT or in other modes while the blowdown valve is closed. This or other modes before occurs only after initially loading the compressor unit.
- Page 74 Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.