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Related Manuals for Gardner Denver AUTO SENTRY EAU99P
Summary of Contents for Gardner Denver AUTO SENTRY EAU99P
- Page 1 13-10-615 Version: 03 July 31, 2009 ELECTRA-SAVER STATIONARY BASE-MOUNTED COMPRESSOR ® AUTO SENTRY -- ES+ CONTROLS DOMESTIC MODELS EAU99P – 200, 250, 300 HP INTERNATIONAL MODELS EAU99R, EAU99S – 150, 186, 225 KW OPERATING AND SERVICE MANUAL...
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Page 2: Maintain Compressor Reliability And Performance With
Reliability in materials and quality assurance is incorporated in our genuine replacement parts. Your authorized Gardner Denver Compressor distributor offers all the backup you’ll need. A worldwide network of authorized distributors provides the finest product support in the air compressor industry. -
Page 3: Warning - Prohibition - Mandatory Label Information
WARNING – PROHIBITION – MANDATORY LABEL INFORMATION 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 maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment. - Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.
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Page 5: Safety Precautions
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 6: Table Of Contents
TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services............1 Instructions For Ordering Repair Parts ......................1 Warning – Prohibition – Mandatory Label Information.................. 2 Safety Precautions ............................4 Index................................6 List Of Illustrations............................8 Section 1, General Information ........................ -
Page 7: Index
INDEX Addition Of Oil Between Changes ....47 Lubrication, Section 5 ........40 Air Filter Element Life........61 Air Filter, Section 6...........60 Maintenance Schedule, Section 8 ....65 Air Flow In The Compressor System ....9 Moisture Separator/Trap........17 Air-Cooled Units, Location .......14 Motor Lubrication .......... - Page 8 Every 8000 Hours Operation......65 Troubleshooting, Section 9 ......67 Every Year............66 Turn Valve............10 Motor Lubrication..........65 Oil Separator ..........65 Warning – Prohibition – Mandatory Label Service Check List Information ............. 2 Air Filter ............65 Water Flow Control Valve For Heat Exchanger Starting &...
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Page 9: List Of Illustrations
LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ........................9 Figure 1-2 - Starter Box..........................10 Figure 1-3 – Package – Controller & Starters ..................... 10 Figure 1-4 – Package – Drive Motor & Air Filter ..................11 Figure 1-5 – Package – Oil Filter, Oil Level Gauge, Mixing Valve.............. 11 Figure 1-6 –... -
Page 10: Section 1, General Information
GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads. -
Page 11: Figure 1-2 - Starter Box
LUBRICATION, COOLING AND SEALING - Oil is forced by air pressure from the oil reservoir through the oil cooler, thermostatic mixing valve, and oil filter and discharges into the compressor main oil gallery. A portion of the oil is directed through internal passages to the bearings, gears and shaft oil seal. The balance of the oil is injected directly into the compression chamber to remove heat of compression, seal internal clearances and lubricate the rotors. -
Page 12: Figure 1-4 - Package - Drive Motor & Air Filter
201EAU797 (Ref. Drawing) Figure 1-4 – PACKAGE – DRIVE MOTOR & AIR FILTER Figure 1-5 – PACKAGE – OIL FILTER, OIL LEVEL GAUGE, MIXING VALVE MINIMUM PRESSURE VALVE & CHECK VALVE 201EAU797 (Ref. Drawing) 13-10-615 Page 11... -
Page 13: Figure 1-6 - Package - Air/Oil Flow Diagram
202EDM797 (Ref. Drawing) Figure 1-6 – PACKAGE – AIR/OIL FLOW DIAGRAM 13-10-615 Page 12... -
Page 14: Section 2, Installation
SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible. Do not electric weld on the compressor or base; bearings can be damaged by passage of current. -
Page 15: Figure 2-1 - Typical Compressor Room
Figure 2-1 – TYPICAL COMPRESSOR ROOM Minimum Air Flow * for Compression and Cooling – CFM /MIN) Air-Cooled Air-Cooled Water-Cooled (Kw) Package Module Package 200 (150) 28,500 (808) 20,500 (580) 8,000 (226) 250 (186) 35,900 (1016) 26,000 (736) 9,900 (280) 300 (225) 37,900 (1073) 26,000 (736) - Page 16 Use of improper solution may result in damage to the cooler. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be made at a maximum 10°...
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Page 17: Figure 2-3 - Cold Weather Installation
Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000SP lubricant. Monitor the unit carefully during start-up and operation to be sure it is functioning normally. -
Page 18: Figure 2-4 - Inlet Line Lengths
Refer to Engineering Data Sheet 13-9-411, available from an authorized Gardner Denver distributor, for the advantages of using the heat recovered from rotary compressors. This heat recovery could easily pay for an adequate shelter for the unit. - Page 19 When connecting two or more GD rotary screw units on a common manifold, each unit is isolated by the check valve in the unit discharge line. If a Gardner Denver rotary screw unit is connected to another compressor on a common manifold, be sure the other compressor has a check valve in the line between the machine and the manifold.
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Page 20: Figure 2-5 - Heat Exchanger Approximate Water Flow
HEAT EXCHANGER (INTERNATIONAL) Water Temperature to Heat Exchanger Approximate Water (ls) Maximum Pressure Drop @ 32° C Water Flow Water Temperature Model 16° C 21° C 27° C 32° C (ls) * (bar) EAU99R & S Less than .15 bar for any flow rate shown in the EAU99R &... -
Page 21: Figure 2-7 - Series Piping
BLOWDOWN VALVE PIPING - The blowdown valve is piped back into the airend between the inlet valve and air filter. WATER PIPING (Water-Cooled Heat Exchanger Models Only) - On machines equipped with water- cooled heat exchangers, the water inlet and outlet connections are located in the unit base flange. It is mandatory that any water cooled unit be installed in a shelter heated to temperatures above freezing (32°... -
Page 22: Figure 2-8 - Parallel Piping
306EAQ797-A (Ref. Drawing) Figure 2-8 – PARALLEL PIPING * (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY 13-10-615 Page 21... - Page 23 PARALLEL PIPING (Figure 2-8, page 21) - A separate water control valve is required to control the discharge air temperature. If a remote (externally mounted) water-cooled aftercooler is piped in parallel with the heat exchanger, provide a separate water control valve for the aftercooler and pipe separate inlet water lines to both the aftercooler and heat exchanger.
- Page 24 Wipe lubrication fitting clean and add grease with a hand-operated grease gun. Only enough grease should be added to replace the grease used by the bearing. Too much grease can be as harmful as insufficient grease. The grease capacity should be about ½ full. Leave the relief plug temporarily off.
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Page 25: Section 3, Starting & Operating Procedures
Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the red “ADD OIL” range. Do not mix different type oils. The unit is shipped filled with Gardner Denver AEON™ 9000SP Lubricating Coolant which is suitable for the first 8000 hours under normal operating conditions. - Page 26 Grounding - Equipment must be properly grounded according to Table 250-95 of the National Electrical Code. Failure to properly ground the compressor package could result in controller malfunction. Rotation - Check for correct motor rotation using “JOG MODE.” Compressor drive shaft rotation must be counterclockwise standing facing the compressor coupling.
- Page 27 The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide open.
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Page 28: Section 4, Controls & Instrumentation
SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver rotary screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line (and to the appropriate water supply if water cooled). -
Page 29: Figure 4-1 - Schematic Tubing Diagram
When the relief valve opens, a stream of high velocity air is released, resulting in a high noise level and possible discharge of accumulated dirt or other debris. Always wear eye and ear protection and stand clear of the discharge port when testing the relief valve to prevent injury. -
Page 30: Figure 4-2 - Blowdown Valve
The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. Figure 4-3 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE... -
Page 31: Figure 4-4 - Inlet Valve
Inlet Valve (Figure 1-4, page 2, and Figure 4-4, page 30) - The Inlet valve restricts the inlet to control delivery and closes to unload the compressor. At shutdown, the inlet valve closes to prevent the back flow of air. The inlet valve position is controlled by air pressure in its piston cylinder, which is controlled by the “AutoSentry”... -
Page 32: Figure 4-5 - Shuttle Valve
Figure 4-5 – SHUTTLE VALVE Purge Air Valve - The purge valve is a normally closed two-way air actuated valve that admits purge air from the final discharge manifold to the compressor to counteract the oil knock that occurs in oil-flooded rotary screw compressors when they are completely unloaded with pressure in the oil reservoir. - Page 33 Solenoid Valves TVC and TVO - These valves control position of the turn valve in response to signals from the “AutoSentry” controller. With both valves de-energized, equal pressure is supplied to both sides of the actuator to hold it in its current position. If TVC only is energized, the right side of the turn valve actuator is exhausted to the compressor inlet cavity, causing the turn valve to move towards the full load position.
- Page 34 COMPRESSOR CAPACITY CONTROL The capacity of the compressor is controlled by the action of the Turn Valve and the Compressor Inlet Valve. The turn valve controls compressor delivery to match demands of 40% to 100% of the compressor’s maximum capacity. The inlet valve throttles to control compressor delivery to match demands of 0% to 40% of the compressors maximum capacity.
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Page 35: Figure 4-7 - Control Schematic - Compressor At Full Load
206EAU797-B (Ref. Drawing) Figure 4-7 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD... -
Page 36: Figure 4-8 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch Off
207EAU797-B (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF... -
Page 37: Figure 4-9 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch On
208EAU797-B (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH ON... -
Page 38: Figure 4-10 - Wiring Diagram - (Wye Delta, Es+ Controller, Air-Cooled)
202EAU546-D (Ref. Drawing) Figure 4-10 – WIRING DIAGRAM – (WYE DELTA, ES+ CONTROLLER, AIR-COOLED) -
Page 39: Figure 4-11 - Wiring Diagram - (Wye Delta, Es+ Controller - Water Cooled)
205EAU546-D (Ref. Drawing) Page 1 of 2 Figure 4-11 – WIRING DIAGRAM – (WYE DELTA, ES+ CONTROLLER – WATER COOLED) - Page 40 205EAU546-D (Ref. Drawing) Page 2 of 2...
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Page 41: Section 5, Lubrication - Oil Cooler, Oil Filter & Separator
OIL SPECIFICATIONS: EAU (Domestic and International) - The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant which can be used for year-round operation. AEON 9000SP is a synthetic, extended life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based lubricant. - Page 42 HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000SP lubricating coolant will operate at a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is encountered, lubricant life will be shortened, see Figure 5-7, page 49.
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Page 43: Figure 5-1 - Dew Point Chart °F
Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F Figure 5-1 – DEW POINT CHART °F Dew -Point Tem perature vs. Am bient Tem perature (100% Relative Hum idity) 6.9 bar 8.6 bar 10.4 bar 12.1 bar... -
Page 44: Figure 5-3 - Flow Diagram
210EAU797-B (Ref. Drawing) Figure 5-3 – FLOW DIAGRAM... -
Page 45: Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted
202EAU797 (Ref. Drawing) 205EDM797 (Ref. Drawing) Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED 13-10-615 Page 44... -
Page 46: Figure 5-5 - Cooler Drain Detail
REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the enclosure. - Page 47 AFTERCOOLER PIPING - At shutdown of the system, all units should be drained completely of condensate if there is any possibility of freezing or corrosion damage. To help remove the condensate, the cooler may be tapped per Figure 5-5, page 45, and a drain cock installed. After opening the drain cock, blow air into the cooler from a connection on the opposite side of the cooler.
- Page 48 Kit number 205EAU4013 including the oil stop valve, check valve and flanges must be installed on all remote elevated coolers per Figure 5-4, page 44, and the following instructions: Mount the check valve (90J113) as shown. Mount the drain valves in the lowest section of the pipe on each side of the cooler connections. Mount the oil stop valve (90AR243) in the line after the thermal mixing valve as shown.
- Page 49 Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. Excessive oil carry-over can damage equipment. Never fill oil reservoir above the "FULL" marker. LUBRICANT CHANGE PROCEDURE - Upgrading to a longer life lubricant is essentially a very worthwhile practice.
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Page 50: Figure 5-6 - Oil Level Gauge
Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user. Gardner Denver offers a free oil analysis program with AEON lubricants. The first sample from a new unit should be sent in after 100 hours. - Page 51 DRAINING AND CLEANING OIL SYSTEM Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation.
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Page 52: Figure 5-8 - Approximate Oil System Capacities
FILLING OIL RESERVOIR Air/oil under pressure will cause severe personal injury or death. Shut down compressor, relieve system of all pressure, disconnect, lockout and tagout power supply to the starter before removing valves, caps, plugs, fittings, bolts and filters. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, tag and lockout the power supply to the starter. - Page 53 COMPRESSOR OIL FILTER ( , page 43) - This patented design screw-i oil filter is a vital part in Figure 5-3 maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is integrated into the replaceable oil filter element. Air/oil under pressure will cause severe personal injury or death.
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Page 54: Figure 5-9 - Thermostatic Mixing Valve Element
To remove the oil filter, using a 1” socket unthread the oil filter from the housing. Rotate the filter head (aluminum assembly) to align the channel in the head with the tabs on the oil filter element.. Lift the threaded part of the filter head until it is seated against the top of the filter head. With the channel aligned and the threaded portion of the filter head against the top of the filter head, disassemble the filter element from the filter head. - Page 55 THERMAL CONTROL (THERMOSTATIC MIXING) VALVE is installed in system as shown in Figure 5-3 page 43. This valve is used to control temperature of the oil in both air-cooled radiator and water-cooled heat exchanger type oil cooler systems. On start-up with unit cold, element is open to bypass, allowing oil to pass directly from the reservoir to compressor during warm-up.
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Page 56: Figure 5-10 - Water Control Valve
In many instances, the cooling water supply for the heat exchanger will contain impurities in solution and/or suspension. These substances can cause scale formation, corrosion and plugging of any water- cooled heat exchanger equipment. Disregarding the possibility that one or more of these conditions exist may result in increased maintenance and operation expense, reduced equipment life and emergency shutdown. -
Page 57: Figure 5-11 - Oil Separator
If the leak develops through the packing, tighten the packing gland nut firmly with a wrench to reseat the packing around the valve stem, then back off the nut until loose, and finally retighten the nut finger tight. Tightening the packing nut too tight may cause erratic operation. An occasional drop of oil on the valve stem at the packing nut will prolong packing life. - Page 58 Oil impinging on the inside of the separator element drains directly back into the oil reservoir by gravity. Oil collected outside the element is returned through tubing to the compressor cylinder. Oil carryover through the service lines may be caused by a faulty oil separator, faulty minimum pressure valve, over-filling of the oil reservoir, oil that foams, oil return line malfunction or water condensate in the oil.
- Page 59 Removal Of Oil Separator For Inspection Or Replacement: Be certain unit is completely off and that no air pressure is in the oil reservoir. Disconnect, tag and lockout power supply to the starter. Remove screws holding the top plate to the separator housing. Lift the top plate from the separator housing.
- Page 60 Oil Cooler Temperature Differential (Water-Cooled Heat Exchanger) - The oil temperature differential depends on the inlet water temperature and the water flow rate permitted by the water flow control valve setting. The oil inlet temperature is approximately the same as the air discharge temperature - see the gauge on the instrument panel.
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Page 61: Section 6, Air Filter
Filter Element - Service the air filter element when the “CHANGE AIR FILTER” LED is illuminated. Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor. - Page 62 Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water. Improper cleaning may damage the element. NOTICE Never operate the unit without the element. Never use elements that are damaged, ruptured or wet. Never use gaskets that won't seal. Keep spare elements and gaskets on hand to reduce downtime.
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Page 63: Section 7, Coupling
SECTION 7 COUPLING Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS Rotating machinery can cause personal injury or death. Turn the unit completely off, open the main disconnect, lockout and tagout before servicing the coupling. COUPLING - The motor and compressor are direct connected by a resilient type flexible coupling with a single element cushion. - Page 64 ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR (see Figure 7-1). NOTICE Elements with non-uniform cross sections must be mounted with the rotation arrow on the coupling the same direction as the rotation arrow on the airend. Incorrect rotation will greatly decrease the torque carrying capacity of the coupling.
- Page 65 3. Apply a light oil or grease film to both sides of the hardened steel washer. This is very important, since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws. Place the supplied hardened washers under the cap screw heads and torque the screws down to the torque rating in the assembly instructions supplied with the coupling.
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Page 66: Section 8, Maintenance Schedule
SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. If the “CHANGE AIR FILTER” message is displayed, air filter requires servicing or changing. See “Air Filter", Section 6. Oil Separator - Operating conditions determine frequency of service. If the “CHANGE SEPARATOR” message is displayed, the oil separator element requires changing. - Page 67 Every Year Check the relief valve for proper operation. See Section 4. Check shutdowns for proper operation. MAINTENANCE SCHEDULE Maintenance Action As Indicated by Every Every Every Every AutoSentry Every 8 1000 8000 * Year Controller Hours Hours Hours Hours •...
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Page 68: Section 9, Troubleshooting
SECTION 9 TROUBLESHOOTING 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 and muffler. - Page 69 SYMPTOM POSSIBLE CAUSE REMEDY Wye Delta switch time set Contact your Gardner Compressor starts too slowly too long. Denver distributor. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Restricted air filter. Clean or replace filter.
- Page 70 NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-10-615 Page 69...
- Page 71 GENERAL PROVISIONS AND LIMITATIONS Gardner Denver (the “Company”) warrants to each original retail purchaser (“Purchaser”) of its new products from the Company or its authorized distributor that such products are, at the time of delivery to the Purchaser, made with good material and workmanship. No warranty is made with respect to: Any product which has been repaired or altered in such a way, in the Company’s judgment, as to affect the product adversely.
- Page 72 Gardner Denver Compressor Division, 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 FAX: (217) 224-7814 Specifications subject to change without notice. Visit our Web Site: www.gardnerdenver.com Copyright © 2009 Gardner Denver, Inc. Litho in U.S.A. Sales and Service in all major cities.