Gardner Denver AUTOSENTRY EAQ99Q Operating And Service Manual Download

Page: 1 / 75

13-9-666

Version: 02

July 20, 2009

ELECTRA-SAVER

ELECTRA-SAVER II

STATIONARY BASE-MOUNTED

COMPRESSOR

AUTOSENTRY

-- ES+ CONTROLS

DOMESTIC MODELS

EAQ99Q, EBQ99M - 125, 150, 200 HP

EAU99Q, EBU99C - 200 HP

INTERNATIONAL MODELS

EAQ99R - 100, 125, 150 HP

(75, 93, 112 KW)

EBQ99N - 125, 150 HP

(93,

112

KW)

EBU99D - 200HP

(150

KW)

OPERATING AND

SERVICE MANUAL

Summary of Contents for AUTOSENTRY EAQ99Q

Page 1: ...II STATIONARY BASE MOUNTED COMPRESSOR AUTOSENTRY ES CONTROLS DOMESTIC MODELS EAQ99Q EBQ99M 125 150 200 HP EAU99Q EBU99C 200 HP INTERNATIONAL MODELS EAQ99R 100 125 150 HP 75 93 112 KW EBQ99N 125 150 H...

Page 2: ...nicians are factory trained and skilled in compressor maintenance and repair They are ready to respond and assist you by providing fast expert maintenance and repair services For the location of your...

Page 3: ...mical operation and minimum downtime Boxed text formats are used within this manual to alert users of the following conditions Safety Labels are used within this manual and affixed to the appropriate...

Page 4: ...low level of risk which if not avoided MAY result in a minor or moderate injury Burn Hazard Hot surface PROHIBITION MANDATORY ACTION REQUIREMENTS Do not Operate Compressor with Guard Removed Do Not Li...

Page 5: ...r oil system until the unit is shut down and the air pressure has been relieved Electrical shock can and may be fatal Perform all wiring in accordance with the National Electrical Code NFPA 70 and any...

Page 6: ...edures 24 Section 4 Controls Instrumentation 27 Section 5 Lubrication Oil Cooler Oil Filter Separator 45 Section 6 Air Filter 63 Section 7 Coupling 65 Section 8 Maintenance Schedule 68 Section 9 Troub...

Page 7: ...High Temperature Operation 46 Inlet Line 17 Inlet Screen And Tube 64 Inlet Valve 30 Installation For Cold Weather Operation 16 Installation Section 2 13 Lifting Unit 13 Location 14 Air Cooled Units 14...

Page 8: ...ting 70 Series Piping 21 Service Check List 68 Every 1000 Hours Operation 68 Every 125 Hours Operation 68 Every 8 Hours Operation 68 Every 8000 Hours Operation 68 Every Year 68 Motor Lubrication 68 Oi...

Page 9: ...rol Schematic Compressor At Full Load Constant Speed Mode 36 Figure 4 9 Control Schematic Compressor Unloaded Low Demand Mode Or Auto Mode 37 Figure 4 10 Control Schematic Compressor At Full Load 38 F...

Page 10: ...r 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 meshi...

Page 11: ...s injected directly into the compression chamber to remove heat of compression seal internal clearances and lubricate the rotors TURN VALVE ELECTRA SAVER ONLY The turn valve is a rotary helical valve...

Page 12: ...13 9 666 Page 11 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 200EDM797 A Ref Drawing...

Page 13: ...13 9 666 Page 12 Figure 1 6 AIR OIL FLOW DIAGRAM 202EDM797 Ref Drawing...

Page 14: ...olling on bars Lift compressor package by base only Do not use other places such as motors compressors or discharge manifold piping as lifting points The eyebolts or lugs provided on the motors are fo...

Page 15: ...nt on all air cooled units The air cooled unit with the standard enclosure requires sufficient flow Figure 2 2 for the compressor oil aftercooling system and for electric motor cooling Air is drawn in...

Page 16: ...mounting bolts and shims to provide uniform support for the base OIL RESERVOIR DRAIN The oil drain is piped from the bottom of the reservoir to the side of the frame This drain is approximately 4 50 i...

Page 17: ...ust 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 sure all drains t...

Page 18: ...iliary air receiver is not required if the piping system is large and provides sufficient storage capacity to prevent rapid cycling When used an air receiver should be of adequate size provided with a...

Page 19: ...severe injury or death Consult filtration specialists for additional filtration and treatment equipment to meet health and safety standards BLOWDOWN VALVE PIPING The blowdown valve is piped back into...

Page 20: ...25 HP EAQ99Q 1 9 2 4 3 2 4 8 55 125 HP EBQ99M 1 8 2 2 3 0 4 5 55 150 HP EAQ99Q 2 3 2 9 3 9 5 8 55 150 HP EBQ99M 2 1 2 6 3 4 5 2 55 200 HP EAQ99Q 2 9 3 6 4 9 7 3 110 200 HP EAU99Q 3 0 3 7 5 0 7 5 110 2...

Page 21: ...low rates shown are approximate and a guide to sizing piping cooling tower and other water system equipment The heat exchanger system is designed to operate with water inlet temperatures from 60 F to...

Page 22: ...ING SERIES PIPING Figure 2 7 Water flow must be through aftercooler first for effective cooling of discharge air and is so piped on the standard water cooled unit Figure 2 8 PARALLEL PIPING 306EAQ797...

Page 23: ...rip proof motor a NEMA 12 starter and control enclosure See Section 2 Location paragraph for distance to the nearest obstruction on starter and control box sides of the unit Lower operating voltages 2...

Page 24: ...mful as insufficient grease The grease cavity should be about 1 2 full 5 Leave the relief plug temporarily off Reconnect the unit and run for about 20 minutes to expel the excess grease 6 Stop the uni...

Page 25: ...CE E E Regular maintenance and replacement at required intervals of the oil filter air filter and air oil separator is necessary to achieve maximum service and extended drain intervals of AEON 9000 SP...

Page 26: ...om the compressor inlet When checking motor rotation induce minimum rotation less than one revolution if possible Never allow motor to reach full speed The compressor unit s direction of rotation must...

Page 27: ...UTO buttons Since the unit is equipped with a minimum 65 psig 4 5 bar pressure discharge valve no special procedure to maintain unit reservoir pressure is required Unit Hot No warm up period is requir...

Page 28: ...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 Automatic restarting or electrical...

Page 29: ...clear of the discharge port when testing the pressure relief valve to prevent injury Never paint lubricate or alter a relief valve Do not plug vent or restrict discharge Operation of the unit with imp...

Page 30: ...rovided to ensure that the inlet valve is closed during blowdown Oil Level Gauge Figure 1 6 page 12 This gauge is located on the oil reservoir and indicates the oil level See Section 5 for information...

Page 31: ...from the power supply lockout and tagout then unscrew the valve cap from the body The internal parts will come out after the cap has been removed Repair kits are available from your local authorized...

Page 32: ...The regulator should be set for 25 30 psig Figure 4 5 SHUTTLE VALVE Shuttle Valve Figure 4 5 Also known as a double check valve the shuttle valve is a device which will take two 2 supply signals and a...

Page 33: ...ape the cylinder walls when moving the pistons Solenoid Valves TVC and TVO Electra Saver only These valves control the position of the turn valve in response to signals from the AutoSentry controller...

Page 34: ...e for several input voltages refer to the transformer label for connection prior to energizing Two primary and one secondary fuse are provided Refer to adjacent labeling for replacement information Te...

Page 35: ...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 Example with normal setting of 100...

Page 36: ...13 9 666 Page 35 Figure 4 7 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE EBQ EBU UNITS ONLY 209EDM797 A Ref Drawing...

Page 37: ...13 9 666 Page 36 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE EBQ EBU UNITS ONLY 211EDM797 A Ref Drawing...

Page 38: ...13 9 666 Page 37 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE OR AUTO MODE EBQ EBU UNITS ONLY 213EDM797 A Ref Drawing...

Page 39: ...13 9 666 Page 38 Figure 4 10 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD EAQ EAU UNITS ONLY 210EDM797 A Ref Drawing...

Page 40: ...13 9 666 Page 39 Figure 4 11 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF EAQ EAU UNITS ONLY 212EDM797 A Ref Drawing...

Page 41: ...13 9 666 Page 40 Figure 4 12 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE SWITCH ON EAQ EAU UNITS ONLY 214EDM797 A Ref Drawing...

Page 42: ...13 9 666 Page 41 Figure 4 13 WIRING DIAGRAM WYE DELTA EBQ EBU UNITS 300EDM546 A Ref Drawing...

Page 43: ...13 9 666 Page 42 Figure 4 14 WIRING DIAGRAM FULL VOLTAGE EBQ EBU UNITS 302EDM546 Ref Drawing...

Page 44: ...13 9 666 Page 43 Figure 4 15 WIRING DIAGRAM WYE DELTA EAQ EAU UNITS ONLY 301EAQ546 B Ref Drawing...

Page 45: ...13 9 666 Page 44 Figure 4 16 WIRING DIAGRAM FULL VOLTAGE EAQ EAU UNITS ONLY 303EAQ546 Ref Drawing...

Page 46: ...o the 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 distr...

Page 47: ...midity 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 compressor over si...

Page 48: ...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 49: ...13 9 666 Page 48 Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM 203EDM797 A Ref Drawing...

Page 50: ...13 9 666 Page 49 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED COOLER 204EAQ797 A Ref Drawing 205EDM797 Ref Drawing...

Page 51: ...the cooler to avoid transmitting piping weight or vibrations to the cooler elements Before beginning installations check to be sure that no debris or foreign matter remains in the couplings or cooler...

Page 52: ...ng module from the package for remote operation the oil stop valve and the check valve that are shipped loose should be mounted as close to the compressor package as possible Flexible connections shou...

Page 53: ...of the green range is shown in Figure 5 6 page 53 Repeated addition of oil between oil changes may indicate excessive oil carryover and should be investigated Air oil under pressure will cause severe...

Page 54: ...Figure 1 6 page 12 and Figure 5 6 indicates the amount of oil in the oil reservoir Read oil level only when unit is on In operation the oil level will fluctuate as the compressor loads and unloads Ad...

Page 55: ...the complete system Draining when the oil is hot will help to prevent varnish deposits and carry away impurities To drain the system use one of the following methods 1 If the unit is not elevated high...

Page 56: ...ecessary 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...

Page 57: ...ressor 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 cha...

Page 58: ...oled 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 As oil warms element grad...

Page 59: ...pment 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 It is strongly rec...

Page 60: ...be should be carefully coiled and placed so that damage will not occur in normal maintenance or traffic past the unit If a leak develops through the packing tighten the packing gland nut firmly with a...

Page 61: ...ne is functioning properly and there is not water or an oil water emulsion in the oil Oil carryover malfunctions of the oil separator are usually due to using elements too long heavy dirt or varnish d...

Page 62: ...and that no air pressure is in the oil reservoir 2 Disconnect lockout and tagout power supply to the starter 3 Remove screws holding the top plate to the separator housing Lift the top plate from the...

Page 63: ...bar receiver pressure Check that oil inlet pressure is correct or measure the differential between drains on the oil cooler shell Oil Cooler Temperature Differential Air Cooled Radiator The oil tempe...

Page 64: ...hen 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...

Page 65: ...to reduce downtime Store elements in a protected area free from damage dirt and moisture Handle all parts with care Filter Element Life The element should be replaced after six 6 cleanings or if 1 Vi...

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: ...her 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 I...

Page 68: ...c element 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 al...

Page 69: ...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 Every 125 Hours Operation 1 Check for dirt accumul...

Page 70: ...ry 8000 Hours Every Year Change Air Filter Change Oil Separator Check Reservoir Oil Level Check for Proper Load Unload Check Discharge Pressure Temp Check Dirt Accumulation on Cooler Change Oil Filter...

Page 71: ...rge 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 investiga...

Page 72: ...ound 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 con...

Page 73: ...000SP lubricating coolant 6 Inoperative minimum pressure valve 6 Replace seals in valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharge Air Temperature this sect...

Page 74: ......

Page 75: ...ompressor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 FAX 217 224 7814 Visit our Web Site www gardnerdenver com Sales and Service in all major cities Specifications s...

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