Gardner Denver AUTO SENTRY EAU99G Operating And Service Manual Download

Page: 1 / 75

GARDNER DENVER

13-10-614

Version: 04

October 29, 2003

ELECTRA-SAVER

STATIONARY BASE-MOUNTED

COMPRESSOR

AUTO SENTRY



-- ES+ CONTROLS

DOMESTIC MODELS

EAU99G & M – 200, 250 & 300 HP

INTERNATIONAL MODEL

EAU99H – 150, 186 & 225 KW

OPERATING AND

SERVICE MANUAL

Summary of Contents for AUTO SENTRY EAU99G

Page 1: ...10 614 Version 04 October 29 2003 ELECTRA SAVER STATIONARY BASE MOUNTED COMPRESSOR AUTO SENTRY ES CONTROLS DOMESTIC MODELS EAU99G M 200 250 300 HP INTERNATIONAL MODEL EAU99H 150 186 225 KW OPERATING A...

Page 2: ...actory tested AEON compressor lubricants specifically formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the necessary parts to simplify servicing your compre...

Page 3: ...ge if the warning is ignored WARNING Warning is used to indicate the presence of a hazard which can cause severe personal injury death or substantial property damage if the warning is ignored CAUTION...

Page 4: ...structions For Ordering Repair Parts i Foreword ii Section 1 General Information 1 Section 2 Installation 9 Section 3 Starting Operating Procedures 20 Section 4 Controls Instrumentation 23 Section 5 L...

Page 5: ...icant Change Procedure 45 Lubrication Motor 19 Lubrication Cooling And Sealing 2 Lubrication Section 5 37 Maintenance Schedule Section 8 62 Moisture In The Oil System 38 Moisture Separator Trap 13 Mot...

Page 6: ...ilter 62 Starting Operating Procedures Section 3 20 Starting The Unit 22 Unit Cold 22 Unit Hot 22 Stopping The Unit 22 Thermal Control Thermostatic Mixing Valve 50 Troubleshooting Section 9 64 Turn Va...

Page 7: ...lve 26 Figure 4 5 Blowdown Valve 27 Figure 4 6 Turn Valve Actuator Sectioned 28 Figure 4 7 Control Schematic Compressor At Full Load 30 Figure 4 8 Control Schematic Compressor Fully Unloaded Low Deman...

Page 8: ...air is drawn into the cavity between the main rotor lobes and secondary rotor grooves A When the rotors pass the inlet port cutoff air is trapped in the interlobe cavity and flows axially with the mes...

Page 9: ...s 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 TURN VALVE The turn valve...

Page 10: ...13 10 614 Page 3 Figure 1 2 STARTER BOX Figure 1 3 PACKAGE CONTROLLER STARTERS 201EAU797 Ref Drawing...

Page 11: ...13 10 614 Page 4 Figure 1 4 PACKAGE DRIVE MOTOR AIR FILTER 201EAU797 Ref Drawing...

Page 12: ...13 10 614 Page 5 Figure 1 5 PACKAGE OIL FILTER OIL LEVEL GAUGE MIXING VALVE MINIMUM PRESSURE VALVE CHECK VALVE Figure 1 6 PACKAGE AIR OIL FLOW DIAGRAM 201EAU797 Ref Drawing...

Page 13: ...ring in accordance with the National Electrical Code NFPA 70 and any applicable local electrical codes Wiring and electrical service must be performed only by qualified electricians Open main disconne...

Page 14: ...13 10 614 Page 7 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 15: ...13 10 614 Page 8 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 16: ...curely tightened When lifting the motor the lifting angle must not exceed 15 degrees Failure to observe this warning may result in damage to equipment or personal injury DANGER Compressor air oil rese...

Page 17: ...cooling Air is drawn into the unit at the motor side of the enclosure and is exhausted at the oil cooler side Do not block the air flow to and from the unit Allow three and one half 3 1 2 feet 1 1 m...

Page 18: ...e bottom of the reservoir to the side of the frame This drain is approximately 4 50 inches 115 mm above the floor level If this is not sufficient to conveniently drain the oil some other methods of pr...

Page 19: ...ide installation must be made the precautions required will depend on the severity of the environment The following are general guidelines for outside installations Cold Weather Down To 10 F 12 C 1 Be...

Page 20: ...sed to keep the compressor room above freezing will save many complications in the operation and installation of the unit Refer to Engineering Data Sheet 13 9 411 available from an authorized Gardner...

Page 21: ...cated at the right hand corner of the unit viewed from the opposite end from control panel side When manifolding two or more rotary screw units on the same line each unit is isolated by the check valv...

Page 22: ...imum Water Flow gpm Approximate Water Pressure Drop 90 F Water Temperature psi 200 EAU99G M 3 0 3 7 5 0 7 5 110 250 EAU99G M 3 8 4 8 6 4 9 5 110 300 EAU99G M 4 6 5 8 7 7 11 6 110 Less than 1 psi for a...

Page 23: ...ure 2 6 page 15 at a minimum pressure of 40 psig 2 8 bar maximum allowable water pressure is 150 psig 10 3 bar The water flow rates shown are approximate and a guide to sizing piping cooling tower and...

Page 24: ...13 10 614 Page 17 Figure 2 7 SERIES PIPING Figure 2 8 PARALLEL PIPING OPTIONAL WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY 305EAQ797 A Ref Drawing 306EAQ797 A Ref Drawing...

Page 25: ...o connect the unit starter to the correct power supply The standard unit is supplied with an open drip proof motor a NEMA 12 starter and control enclosure See Location paragraph page 9 for distance to...

Page 26: ...ug temporarily off Reconnect the unit and run for about 20 minutes to expel the excess grease 6 Stop the unit Replace the relief plug 7 Restart the unit WARNING Rotating machinery can cause injury or...

Page 27: ...als of AEON 9000SP synthetic lubricant Use only genuine Gardner Denver filters designed and specified for this compressor DANGER Before removing the oil filler plug always stop the unit and release ai...

Page 28: ...an one revolution if possible Never allow motor to reach full speed WARNING The compressor unit s direction of rotation must be checkd every time the compressor is reconnected to the power supply 8 Sy...

Page 29: ...ge valve no special procedure to maintain unit reservoir pressure is required Unit Hot No warm up period is required If the unit is a water cooled heat exchanger model open any manual water inlet valv...

Page 30: ...ge window Press the STOP RESET key at any time to stop the compressor under normal conditions Detailed instructions for the controller are found in the manual 13 9 653 WARNING Automatic restarting or...

Page 31: ...ion and stand clear of the discharge port when testing the relief valve to prevent injury CAUTION Never paint lubricate or alter a relief valve Do not plug vent or restrict discharge WARNING Operation...

Page 32: ...g The valve does not require maintenance or adjustment If the valve fails to function check the valve stem O ring for sealing valve orifices for restriction or valve and valve seat for burrs and dirt...

Page 33: ...inlet piston to allow the valve to open Pressure Regulator The pressure regulator is used to supply a constant and low control pressure to prevent damage to the inlet valve from slamming The regulato...

Page 34: ...the AutoSentry controller for modulation and control Reservoir Pressure Transducer This transducer is connected to the coolant system Its signal is used to prevent loaded starts monitor oil pressure a...

Page 35: ...are open they direct some of the air which would otherwise be compressed back to the inlet reducing both capacity and power consumption Turn Valve Actuator Figure 4 6 The turn valve actuator is a rot...

Page 36: ...r to adjacent labeling for replacement information Terminal Strip This provides connections for all 110 120 volt devices not contained within the enclosure Fan Starter The starter is used to provide c...

Page 37: ...13 10 614 Page 30 Figure 4 7 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 206EAU797 A Ref Drawing...

Page 38: ...13 10 614 Page 31 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF 207EAU797 A Ref Drawing...

Page 39: ...13 10 614 Page 32 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH ON 208EAU797 A Ref Drawing...

Page 40: ...13 10 614 Page 33 Figure 4 10 WIRING DIAGRAM WYE DELTA ES CONTROLLER AIR COOLED 202EAU546 D Ref Drawing Page 1 of 2...

Page 41: ...13 10 614 Page 34 202EAU546 D Ref Drawing Page 2 of 2...

Page 42: ...13 10 614 Page 35 Figure 4 11 WIRING DIAGRAM WYE DELTA ES CONTROLLER WATER COOLED 205EAU546 D Ref Drawing Page 1 of 2...

Page 43: ...13 10 614 Page 36 205EAU546 D Ref Drawing Page 2 of 2...

Page 44: ...he highest quality standards and are factory authorized tested and approved for use in rotary screw compressors AEON lubricants are available through your authorized Gardner Denver compressor distribu...

Page 45: ...nd low relative humidity the thermal mixing valve controls the oil temperature and prevents moisture accumulation in the oil Unusual cooling of the oil reservoir light duty cycles high humidity gross...

Page 46: ...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 The compressor discharge temperat...

Page 47: ...13 10 614 Page 40 Figure 5 3 FLOW DIAGRAM 210EAU797 A Ref Drawing...

Page 48: ...13 10 614 Page 41 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED 205EDM797 Ref Drawing 202EAU797 Ref Drawing...

Page 49: ...ts of local codes should be followed When connecting pipe fittings to the cooler support the threaded coupling with a pipe wrench when tightening the connection Use silicone sealant on all steel to al...

Page 50: ...piped into the minimum pressure check valve then into piping to the cooler with a flexible connection between the minimum pressure check valve and aftercooler to keep the weight of the piping off of t...

Page 51: ...llations with pipe lengths and or vertical runs outside the recommended limits could result in high oil carryover and cause the machine to shutdown on high discharge temperature COLD AMBIENT OPERATION...

Page 52: ...the filter and reinstall used filter 2 Fill the system with a 50 percent charge of the new lubricant Start the machine and stay there to observe Allow the machine to run about five minutes at temperat...

Page 53: ...ompressor is on Drain oil only when the oil level is above the center of the green range on the gauge as read when the compressor is on OIL CHANGE INTERVAL Recommended oil change intervals are based o...

Page 54: ...g and tubing may be at high temperature during and after operation Always drain the complete system Draining when the oil is hot will help to prevent varnish deposits and carry away impurities To drai...

Page 55: ...to bring level to the center of the green range on the gauge On unloaded operation and after shutdown some oil will drain back into the oil reservoir and the oil level gauge will read FULL DO NOT DRAI...

Page 56: ...oper oil filter maintenance will cause damage to equipment Replace filter element every 1000 hours of operation More frequent replacement could be required depending on operating conditions A filter e...

Page 57: ...required on air cooled quiet enclosed machines THERMAL CONTROL THERMOSTATIC MIXING VALVE is installed in system as shown in Figure 5 3 page 40 This valve is used to control temperature of the oil in b...

Page 58: ...y held may indicate tube leakage or fouling and should be investigated In many instances the cooling water supply for the heat exchanger will contain impurities in solution and or suspension These sub...

Page 59: ...ng the capillary tube a kink or break in the tubing or connections will make the valve inoperative Never attempt to change capillary length Excess capillary tube should be carefully coiled and placed...

Page 60: ...of the oil reservoir oil that foams oil return line malfunction or water condensate in the oil If oil carryover occurs inspect the separator only after it is determined that the oil level is not too...

Page 61: ...ntial can cause damage to equipment Replace the separator when the Change Separator advisory appears NOTICE A sudden drop of zero pressure differential or sudden heavy oil carryover may indicate a rup...

Page 62: ...auge on the instrument panel or check with a thermometer at the discharge housing Compressor Oil Inlet Temperature 150 F to 160 F 66 C to 71 C Install a tee at the oil filter outlet and check with a t...

Page 63: ...oled Heat Exchanger The water pressure differential through the heat exchanger will depend on the supply pressure flow rate cooler tube cleanliness and outlet pressure The inlet and outlet water press...

Page 64: ...ine parts are available through your authorized Gardner Denver distributor To service 1 Unfasten the clips and pull out the filter element 2 Visually inspect the element If cleaning is not necessary r...

Page 65: ...al inspection indicates a rupture crack or pin hole in the pleated media Inspection should be done by placing a bright light inside the element 2 Pressure drop through a filter with a freshly cleaned...

Page 66: ...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 wit...

Page 67: ...This is very important since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws 5 Check to see if element is centered between shaft ends If e...

Page 68: ...lement the hardened washer and the cap screw head free from dirt 4 Check to see if element is centered between shaft ends If element is centered using the loctite supplied with the coupling lock all s...

Page 69: ...is high refer to Excessive Oil consumption page 65 DO NOT MIX LUBRICANTS 2 Observe if the unit loads and unloads properly 3 Check discharge pressure and temperature 4 Check Panel LED s for advisories...

Page 70: ...oller Every 8 Hours Every 125 Hours Every 1000 Hours Every 8000 Hours Every Year Change Air Filter Change Oil Separator Check Reservoir Oil Level Check for Proper Load Unload Check Discharge Pressure...

Page 71: ...discharge temperature switch malfunction 2 Replace switch 3 Blown fuse in starter control box 3 Replace fuse investigate if fuses continue to blow 4 Motor starter overload heaters trip 4 Reset and in...

Page 72: ...ks found 5 Aftercooler is frozen 5 Thaw out This machine cannot operate in temperatures below 32 F 0 C 6 Unload pressure adjusted too low 6 Adjust the unload pressure See Manual 13 9 653 Excessive oil...

Page 73: ...ge temperatures 7 Reduce temperature See High Discharge Air Temperature this section 8 Scavenge line check valve failure 8 Replace check valve 9 Water condensate in oil 9 Check oil reservoir temperatu...

Page 74: ...initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized ser...

Page 75: ...rvice Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946...

Search results

Summary of Contents for AUTO SENTRY EAU99G

Reviews:

Related manuals for AUTO SENTRY EAU99G

Brands by name

Popular brands

Gardner Denver AUTO SENTRY EAU99G, Operating And Service Manual

Search results

Summary of Contents for AUTO SENTRY EAU99G

Reviews:

Related manuals for AUTO SENTRY EAU99G

Brands by name

Popular brands