Gardner Denver EAH99C Operating And Service Manual Download

Page: 1 / 76

13-9-663

Version: 02

June 15, 2009

ELECTRA SCREW

ELECTRA-SAVER

ELECTRA-SAVER II

STATIONARY BASE-MOUNTED

COMPRESSOR

AUTO SENTRY

-- ES+ CONTROLS

EAH99C, EBH99G - 40, 50 HP

EAM99C, EBM99K - 60, 75 HP

ERH99E, EAP99J, EBP99J - 100 HP

INTERNATIONAL MODELS

EBM99L 60, 75, 100 HP (45, 56, 75 KW)

OPERATING AND

SERVICE MANUAL

Summary of Contents for EAH99C

Page 1: ...ELECTRA SAVER ELECTRA SAVER II STATIONARY BASE MOUNTED COMPRESSOR AUTO SENTRY ES CONTROLS EAH99C EBH99G 40 50 HP EAM99C EBM99K 60 75 HP ERH99E EAP99J EBP99J 100 HP INTERNATIONAL MODELS EBM99L 60 75 1...

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: ...Controls Instrumentation 26 Section 5 Lubrication Oil Cooler Oil Filter Separator 44 Section 6 Air Filter 63 Section 7 Coupling 65 Section 8 Maintenance Schedule 68 Section 9 Troubleshooting 70 This...

Page 7: ...45 Inlet Line 17 Inlet Screen And Tube 64 Inlet Valve 29 Installation For Cold Weather Operation 16 Installation Section 2 13 Lifting Unit 13 Location 13 Air Cooled Units 14 Water Cooled Units 15 Lub...

Page 8: ...8000 Hours Operation 68 Every Year 68 Motor Lubrication 68 Oil Separator 68 Service Check List Air Filter 68 Shuttle Valve 30 Solenoid Valves Ivc And Ivo 30 Solenoid Valves Tvc And Tvo 31 Starting Ope...

Page 9: ...ll Load Constant Speed Mode 35 Figure 4 9 Control Schematic Compressor Unloaded Low Demand Mode Or Auto Mode 36 Figure 4 10 Control Schematic Compressor At Full Load 37 Figure 4 11 Control Schematic C...

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 9 663 Page 11 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 217ECM797 A Ref Drawing...

Page 13: ...13 9 663 Page 12 Figure 1 6 AIR OIL FLOW DIAGRAM 219ECM797 A Ref Drawing...

Page 14: ...s provided on the motors are for lifting the motors only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting the motors the lifting angle must not...

Page 15: ...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 to the ne...

Page 16: ...il drain is piped from the 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...

Page 17: ...y of the environment The following are general guidelines for outside installations Cold Weather Down To 10 F 12 C 1 Be sure all drains traps and control lines including pressure transducer lines are...

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: ...piped back into the airend between the inlet valve and air filter HEAT EXCHANGER Water Temperature to Heat Exchanger Gallons minute HP Model 60 F 70 F 80 F 90 F Maximum Water Flow Gallons minute Appro...

Page 20: ...PPROXIMATE WATER FLOW 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 fl...

Page 21: ...on on the water system Optional Water Control Valve and Water Shutoff Valve Must Be Ordered Separately Figure 2 7 SERIES PIPING SERIES PIPING Figure 2 7 Water flow must be through aftercooler first fo...

Page 22: ...open drip 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 vol...

Page 23: ...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 24: ...eparator is necessary to achieve maximum service and extended drain intervals of AEON 9000 SP synthetic lubricant Use only genuine Gardner Denver filters designed and specified for this compressor Bef...

Page 25: ...d The compressor unit s direction of rotation must be checkd every time the compressor is reconnected to the power supply 8 System Pressure Set the controls to the desired load pressure DO NOT EXCEED...

Page 26: ...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 27: ...ssage 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 elect...

Page 28: ...lear of the discharge port when testing the 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 improper reli...

Page 29: ...ded 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 on...

Page 30: ...e minimum pressure required to open the valve To service the valve make sure all pressure is relieved disconnect the unit from the power supply lockout and tagout then unscrew the valve cap from the b...

Page 31: ...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 32: ...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 33: ...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 34: ...ands 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 Example with normal sett...

Page 35: ...13 9 663 Page 34 Figure 4 7 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE ERH EBH EBM EBP UNITS ONLY 225ECM797 B Ref Drawing...

Page 36: ...13 9 663 Page 35 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE ERH EBH EBM EBP UNITS ONLY 226ECM797 B Ref Drawing...

Page 37: ...13 9 663 Page 36 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE OR AUTO MODE ERH EBH EBM EBP UNITS ONLY 227ECM797 B Ref Drawing...

Page 38: ...13 9 663 Page 37 Figure 4 10 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD EAH EAM EAP UNITS ONLY 214ECM797 B Ref Drawing...

Page 39: ...13 9 663 Page 38 Figure 4 11 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF EAH EAM EAP UNITS ONLY 215ECM797 B Ref Drawing...

Page 40: ...13 9 663 Page 39 Figure 4 12 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE SWITCH ON EAH EAM EAP UNITS ONLY 216ECM797 B Ref Drawing...

Page 41: ...13 9 663 Page 40 Figure 4 13 WIRING DIAGRAM WYE DELTA EBH EBM EBP UNITS WITH ES CONTROLS 214ECP546 B Ref Drawing...

Page 42: ...13 9 663 Page 41 Figure 4 14 WIRING DIAGRAM FULL VOLTAGE ERH EBH EBM EBP UNITS WITH ES CONTROLS 218ECP546 A Ref Drawing...

Page 43: ...13 9 663 Page 42 Figure 4 15 WIRING DIAGRAM WYE DELTA EAH EAM EAP UNITS WITH ES CONTROLS AND CURRENT MONITOR 216EAP546 B Ref Drawing...

Page 44: ...13 9 663 Page 43 Figure 4 16 WIRING DIAGRAM FULL VOLTAGE EAH EAM EAP UNITS WITH ES CONTROLS AND CURRENT MONITOR 220EAP546 B Ref Drawing...

Page 45: ...s are factory filled with AEON lubricants These lubricants are formulated to the highest quality standards and are factory authorized tested and approved for use in rotary screw compressors AEON lubri...

Page 46: ...alve 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 sizing or malfunctions of the...

Page 47: ...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 48: ...13 9 663 Page 47 Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM 221ECM797 B Ref Drawing...

Page 49: ...13 9 663 Page 48 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED COOLER 201EAP797 A Ref Drawing 218ECM797 A Ref Drawing...

Page 50: ...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 51: ...ving the cooling 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 co...

Page 52: ...nge is shown in Figure 5 6 page 52 Repeated addition of oil between oil changes may indicate excessive oil carry over and should be investigated Air oil under pressure will cause severe personal injur...

Page 53: ...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 Add...

Page 54: ...ystem 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 enough to use...

Page 55: ...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 DRAIN OIL TO CORRECT On the next...

Page 56: ...efer to the parts list for the part number Use the following procedure to replace the filter element Do not disturb the piping Air oil under pressure will cause severe personal injury or death Shut do...

Page 57: ...to the bypass allowing more of the oil from the cooler to mix with oil from the bypass After the unit is warmed up the mixing valve maintains oil injection temperature into the compressor at a minimum...

Page 58: ...itions exist may result in increased maintenance and operation expense reduced equipment life and emergency shutdown It is strongly recommended that a reputable local water treatment concern be engage...

Page 59: ...opposite direction The groove at the lower edge of the adjusting screw is an index line for use with the index scale 0 to 8 in obtaining a desired setting These valves must be handled with care and pr...

Page 60: ...r control and gauge actuation Figure 5 12 OIL SEPARATOR COMPRESSOR GD ELIMINATOR OIL SEPARATOR located in a separate housing consists of a renewable cartridge type separator element and provides the f...

Page 61: ...ator can be determined by pressure differential gauging or by inspection Pressure Differential Gauging The CHANGE SEPARATOR advisory will flash when the pressure differential across the oil separator...

Page 62: ...and center the separator on the chamfer Press separator down into the housing Do not use excessive force as separator damage can occur 8 Place the spacer on the indent in the separator Seat the top p...

Page 63: ...temperature is approximately the same as air discharge temperature see the gauge on the instrument panel The outlet oil temperature may be checked by installing a tee at the oil filter outlet Oil Cool...

Page 64: ...rts are available through your authorized Gardner Denver distributor To service 1 Remove the wingnut and pull out the filter element 2 Visually inspect the element If cleaning is not necessary reinsta...

Page 65: ...upture 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 element is below three 3 in...

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: ...r 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...

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: ...SP 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 sectio...

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Page 76: ...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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