Gardner Denver EAQ99S Operating And Service Manual
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Gardner Denver EAQ99S Operating And Service Manual

Gardner Denver EAQ99S Operating And Service Manual

Electra-saver stationary base-mounted compressor
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13-10-616
CE MARK
Version: 01
August 14, 2009
ELECTRA-SAVER
STATIONARY BASE-MOUNTED
COMPRESSOR
®
AUTO SENTRY
-- ES+ CONTROLS
CE MARK
INTERNATIONAL MODEL
EAQ99S – 75, 93, 112 KW
OPERATING AND
SERVICE MANUAL

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  • Page 1 13-10-616 CE MARK Version: 01 August 14, 2009 ELECTRA-SAVER STATIONARY BASE-MOUNTED COMPRESSOR ® AUTO SENTRY -- ES+ CONTROLS CE MARK INTERNATIONAL MODEL EAQ99S – 75, 93, 112 KW OPERATING AND SERVICE MANUAL...

  • Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services

    For the location of your local authorized Gardner Denver Air Compressor distributor, refer to the yellow pages of your phone directory, check the Gardner Denver Web Site at www.gardnerdenver.com...

  • 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.

  • Page 5: 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 Index................................5 List Of Illustrations............................6 Technical Data Sheets ..........................7 Section 1, General Information ........................

  • Page 6: Index

    INDEX Addition Of Oil Between Changes ........48 Oil Reservoir Drain ..............18 Air Filter Element Life............63 Oil Separator Air Filter, Section 6.............. 62 Compressor (Gd Eliminator) ...........58 Air Flow In The Compressor System ........10 Inspection................59 Air-Cooled Units, Location ..........17 Oil Carryover..............58 Autosentry Operation ............

  • Page 7: List Of Illustrations

    LIST OF ILLUSTRATIONS Figure 1-1 – Compression Cycle ........................ 10 Figure 1-2 – Starter Box..........................12 Figure 1-3 – Package – Cooler & Oil Filter ....................12 Figure 1-4 – Package – Drive Motor & Air Filter ..................13 Figure 1-5 – Package – Inside Control Box ....................14 Figure 1-6 –...

  • Page 8: Technical Data Sheets

    TECHNICAL DATA SHEETS Technical Data Sheet EAQ99S - 75 kw 400 volt 50 hz 7 bar 8.6 bar 10.3 bar Capacity and power: Cagi Pneurop PN2CPTC2 Normal working pressure (bar) 10.3 Capacity at normal working pressure (m3/min) 12.2 11.6 Shaft power at normal working pressure (kw)
  • Page 9 Technical Data Sheet EAQ99S - 93 kw 400 volt 50 hz 7 bar 8.6 bar 10.3 bar Capacity and power: Cagi Pneurop PN2CPTC2 Normal working pressure (bar) 10.3 Capacity at normal working pressure (m3/min) 16.8 13.9 12.1 Shaft power at normal working pressure (kw) Maximum working pressure (bar) 10.3...
  • Page 10 Technical Data Sheet EAQ99S - 112 kw 400 volt 50 hz 7 bar 8.6 bar 10.3 bar Capacity and power: Cagi Pneurop PN2CPTC2 Normal working pressure (bar) 10.3 Capacity at normal working pressure (m3/min) 17.7 16.7 13.9 Shaft power at normal working pressure (kw) Maximum working pressure (bar) 10.3...

  • Page 11: Section 1, General Information

    SECTION 1 GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR - The 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 12 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 13: Figure 1-2 - Starter Box

    200EDM797-A (Ref. Drawing) Figure 1-2 – STARTER BOX Figure 1-3 – PACKAGE – COOLER & OIL FILTER 13-10-616 Page 12...

  • Page 14: Figure 1-4 - Package - Drive Motor & Air Filter

    Figure 1-4 – PACKAGE – DRIVE MOTOR & AIR FILTER 200EDM797-A (Ref. Drawing) 13-10-616 Page 13...

  • Page 15: Figure 1-5 - Package - Inside Control Box

    200EDM797-A (Ref. Drawing) Figure 1-5 – PACKAGE – INSIDE CONTROL BOX 202EDM797 (Ref. Drawing) Figure 1-6 – PACKAGE – AIR/OIL FLOW DIAGRAM 13-10-616 Page 14...
  • Page 16 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 17: 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 18: Figure 2-1 - Typical Compressor Room

    Figure 2-1 – TYPICAL COMPRESSOR ROOM Minimum Air Flow * for Compression and Cooling INTERNATIONAL (M /MIN Air-Cooled Water-Cooled Package Package * 27° C Inlet Air Figure 2-2 – AIR FLOW CHART Air-Cooled Units - A combination oil/aftercooler is supplied as standard equipment on all air-cooled units.
  • Page 19 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°...

  • Page 20: 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 21: 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 22: Figure 2-5 - Heat Exchanger (Oil Cooler) Approximate Water Flow

    Water Flow Pressure Drop @ 32° C (ls) (ls) * Water Temperature Bar Model 16° C 21° C 27° C 32° C EAQ99S 1.41 2.52 Less than .15 bar for any EAQ99S 1.26 1.89 2.52 flow rate shown in the table EAQ99S 1.05...

  • Page 23: Figure 2-6 - Aftercooler Approximate Water Flow

    Pressure Drop @ 32° C (ls) * Water Temperature BAR Model 16° C 21° C 27° C 32° C EAQ99S 3.47 Less than .1 bar for any EAQ99S 3.47 flow rate shown in the table EAQ99S 3.47 * Flows exceeding "Maximum Water Flow" will cause severe erosion and will void unit warranty.

  • Page 24: Figure 2-7 - Series Piping

    305EAQ797-A (Ref. Drawing) Figure 2-7 – SERIES PIPING 306EAQ797-A (Ref. Drawing) Figure 2-8 – PARALLEL PIPING * (OPTIONAL) WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY 13-10-616 Page 23...
  • Page 25 SERIES PIPING (Figure 2-7, page 23) - Water flow must be through aftercooler first for effective cooling of discharge air and is so piped on the standard water-cooled unit. PARALLEL PIPING (Figure 2-8, page 23) - A separate water control valve is required to control the discharge air temperature.
  • Page 26 MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following charts show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions.

  • Page 27: 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 28 Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See FIGURE 4-10 thru FIGURE 4-12, pages 41 thru 42, for general wiring diagrams and Section 2, for installation instructions. Grounding - Equipment must be properly grounded according to Table 250-95 of the National Electrical Code.
  • Page 29 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. Start the unit by pushing either the “CONSTANT RUN” button or one of the “AUTO” buttons. Since the unit is equipped with a minimum (4.5 bar) pressure discharge valve, no special procedure to maintain unit reservoir pressure is required.

  • Page 30: 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 31: 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 32: Figure 4-2 - Minimum Discharge Pressure/Check 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 4-2 – MINIMUM DISCHARGE PRESSURE/CHECK VALVE...

  • Page 33: Figure 4-3 - Inlet Valve

    208EDM797-A (Ref. Drawing) Figure 4-3 – INLET VALVE Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals from the “AutoSentry”. With both valves de-energized, the normally open IVC valve allows control pressure to the inlet piston to close the valve.

  • Page 34: Figure 4-5 - Blowdown 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. This valve is controlled by the same control pressure which controls the inlet valve.
  • Page 35 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.

  • Page 36: Figure 4-6 - Turn Valve Actuator (Sectioned)

    213ECM797-A (Ref. Drawing) Figure 4-6 – TURN VALVE ACTUATOR (SECTIONED) 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.

  • Page 37: Figure 4-7 - Control Schematic - Compressor At Full Load

    210EDM797-A (Ref. Drawing) Figure 4-7 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD...

  • Page 38: Figure 4-8 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch Off

    212EDM797-A (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF...

  • Page 39: Figure 4-9 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch On

    214EDM797-A (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH ON...

  • Page 40: Figure 4-10 - Wiring Diagram - (Wye Delta, Es+ Controller, Air-Cooled)

    301EAQ546-B (Ref. Drawing) Page 1 of 2 Figure 4-10 – WIRING DIAGRAM – (WYE DELTA, ES+ CONTROLLER, AIR-COOLED)
  • Page 41 301EAQ546-B (Ref. Drawing) Page 2 of 2...

  • Page 42: Section 5, Lubrication - Oil Cooler, Oil Filter & Separator

    AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS: - (Both EAU99R & EAQ99S) 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 43 HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000SP lubricating coolant will operate at a sustained discharge temperature up to 99° C. When unusually high ambient air temperature is encountered, lubricant life will be shortened. See Figure 5-6, page 50. Air/oil under pressure will cause severe personal injury or death. Shut down...

  • Page 44: Figure 5-1 - Dew Point Chart ° C

    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 Am bient Tem p. C Figure 5-1 – DEW POINT CHART ° C These charts are easily used by reading the ambient temperature along the bottom axis of the chart and then reading the appropriate pressure curve to determine the corresponding dew-point temperature on the left axis of the chart.

  • Page 45: Figure 5-2 - Flow Diagram

    203EDM797-A (Ref. Drawing) Figure 5-2 – FLOW DIAGRAM...

  • Page 46: Figure 5-3 - Oil Flow Diagram - Remote Overhead Mounted

    204EAQ797-A (Ref. Drawing) 205EDM797 (Ref. Drawing) Figure 5-3 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED 13-10-616 Page 45...

  • Page 47: Figure 5-4 - 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 48 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 5-4, page 46, 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 49 The shipped loose kit includes the oil stop valve, check valve and flanges and must be installed on all remote elevated coolers per Figure 5-3, page 45, 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 50 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.

  • Page 51: Figure 5-5 - 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 the AEON lubricants. The first sample from a new unit should be sent in after 100 hours.
  • Page 52 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.

  • Page 53: Figure 5-7 - 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 54 COMPRESSOR OIL FILTER ( , page 44) - This patented design screw on oil filter is a vital part Figure 5-2 in maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valves are located in the top manifold of the filterstat. To replace, unbolt the manifolds and remove valves.

  • Page 55: Figure 5-8 - Thermostatic Mixing Valve Element

    To remove the oil filter, use a 1” socket to 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 56 To check the element, heat in oil -- it should be fully extended at 66° C. If the unit shuts down due to high air discharge temperature, it may be that one or both thermostatic mixing valve elements ( Figure 5-2 page 44) are stuck open.

  • Page 57: Figure 5-9 - Water Control Valve

    Hex head zinc anodes are used in the return bonnet (opposite end to the water pipe connections) of heat exchangers to provide internal water system corrosion protection. These anodes should be inspected periodically and replaced when the zinc has been reduced to about 13mm in length. Figure 5-9 –...
  • Page 58 WATER SHUTOFF VALVE - WATER-COOLED HEAT EXCHANGER (Optional Equipment) ( Figure 5-2 page - A magnetic solenoid-operated water shutoff valve rated at 10.3 bar water pressure should be mounted in the water outlet line after the oil cooler. The valve should be wired into the compressor control circuit so that the valve opens to allow water to flow any time the compressor is running.

  • Page 59: Figure 5-10 - Oil Separator

    Compressor, air/oil reservoir, separation chamber and all piping and tubing may be at high temperature during and after operation. OIL RESERVOIR - The oil reservoir-separator combines multiple functions into one vessel. The lower half is the oil reservoir, providing oil storage capacity for the system and the top portion, a primary oil separation means.
  • Page 60 Oil separator element life cannot be predicted; it will vary greatly depending on the conditions of operation, the quality of the oil used and the maintenance of the oil and air filters. The condition of the separator can be determined by pressure differential gauging or by inspection. Pressure Differential Gauging - The “CHANGE SEPARATOR”...
  • Page 61 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 62 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.

  • Page 63: 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 64 Allow the element to air dry COMPLETELY. Do not expose the element to heat over 66° C. Install the element in the filter body and fasten securely with the clips. Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water.

  • Page 65: 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 66 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 67 Replacing Element: 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. 1.

  • Page 68: 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 69 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 •...

  • Page 70: 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 71 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 72 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. 13-10-616...
  • Page 73 13-10-616 Page 72...
  • Page 74 For additional information contact your local representative or Gardner Denver Compressor 1800 Gardner Expressway, Quincy, Illinois 62305 Customer Service Department Telephone: (800) 682-9868 Specifications subject to change without notice. FAX: (217) 224-7814 Copyright © 2009 Gardner Denver, Inc. Litho in U.S.A. Visit our Web Site: www.gardnerdenver.com...

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