Gardner Denver EBM99M 60 Operating And Service Manual Download

Page: 1 / 96

13-21-603

Version: 00

December 9, 2014

ELECTRA-SAVER

ELECTRA-SAVER II

STATIONARY BASE-MOUNTED

COMPRESSOR

AirSmart

™

Controller

EAM99E, EBM99M – 60, 75 HP

EAP99L, EBP99L – 100 HP

OPERATING AND

SERVICE MANUAL

Summary of Contents for EBM99M 60

Page 1: ...13 21 603 Version 00 December 9 2014 ELECTRA SAVER ELECTRA SAVER II STATIONARY BASE MOUNTED COMPRESSOR AirSmart Controller EAM99E EBM99M 60 75 HP EAP99L EBP99L 100 HP OPERATING AND SERVICE MANUAL...

Page 2: ...necessary parts to simplify servicing your compressor Authorized distributor service technicians are factory trained and skilled in compressor maintenance and repair They are ready to respond and ass...

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: ...n 9 Section 2 Installation 13 Section 3 Starting Operating Procedures 23 Section 4 Controls Instrumentation 28 Section 5 Lubrication Oil Cooler Oil Filter Separator 65 Section 6 Air Filter 84 Section...

Page 7: ...nlet Line 17 Inlet Screen And Tube 93 Inlet Valve 32 Installation For Cold Weather Operation 16 Installation Section 2 13 Lifting Unit 13 Location 13 Air Cooled Units 14 Water Cooled Units 15 Lubrican...

Page 8: ...Operation 97 Every 8000 Hours Operation 97 Every Year 97 Motor Lubrication 97 Oil Separator 97 Service Check List Air Filter 97 Shuttle Valve 33 Solenoid Valves Ivc And Ivo 33 Solenoid Valves Tvc And...

Page 9: ...ng Diagram Wye Delta Air Cooled Water Cooled 200 230 Volt 60 75 HP 43 Figure 4 15 Wiring Diagram Wye Delta Air Cooled Water Cooled 230 Volt 60 Hp 45 Figure 4 16 Wiring Diagram Wye Delta Air Cooled Wat...

Page 10: ...ir 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 mesh...

Page 11: ...is 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 21 603 Page 11 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 217ECM797 A Ref Drawing...

Page 13: ...13 21 603 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: ...motor 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...

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: ...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 h...

Page 18: ...ry 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 rel...

Page 19: ...t be located between the two units Discharge air used for breathing will cause severe injury or death Consult filtration specialists for additional filtration and treatment equipment to meet health an...

Page 20: ...OW 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 on the left si...

Page 21: ...uling and corrosion If water warmer than 90 F 32 C is used higher compressor oil inlet temperatures and high water usage will result Most water systems will require control of impurities filtration so...

Page 22: ...package is factory wired for all connections from the starter to the motor for the horsepower and voltage specified on the order The standard unit is supplied with open drip proof motors and a UL Type...

Page 23: ...rmful 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 un...

Page 24: ...C 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...

Page 25: ...g 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 be checked every time the compresso...

Page 26: ...en press RUN 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 requi...

Page 27: ...n of the compressor the machine must be stopped and in the Ready mode Stop the compressor by pressing the Stop Reset button The front panel display should read READY on line 3 Next press the Enter but...

Page 28: ...at were made press the Enter button If the Stop Reset button is pressed the parameter changes will be lost the next time the compressor power is turned off Setting The Unload and Load Pressure After s...

Page 29: ...he operating light will be on Press the STOP RESET key at any time to stop the compressor under normal conditions AUTOMATIC is the most common selected mode of operation as it automatically will opera...

Page 30: ...alve raise the system operating pressure to 75 of the relief valve set pressure and manually open the valve with the hand lever Hold the valve open for a few seconds and allow it to snap shut When the...

Page 31: ...tion of the unit with improper relief valve setting can result in severe personal injury or machine damage Ensure properly set valves are installed and maintained Figure 4 2 SCHEMATIC TUBING DIAGRAM 2...

Page 32: ...ided 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 33: ...he 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...

Page 34: ...he regulator should be set for 25 30 psig Figure 4 6 SHUTTLE VALVE Shuttle Valve Figure 4 6 Also known as a double check valve the shuttle valve is a device which will take two 2 supply signals and al...

Page 35: ...are not to scrape 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 AirSmart...

Page 36: ...r supply and control transformer as applicable Terminal Strip This provides connections for all 24 volt DC controlled devices not directly connected to the AirSmart controller Fan Starter The starter...

Page 37: ...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 38: ...13 21 603 Page 37 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE EBH EBM EBP UNITS ONLY 225ECM797 B Ref Drawing...

Page 39: ...13 21 603 Page 38 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE EBH EBM EBP UNITS ONLY 226ECM797 B Ref Drawing...

Page 40: ...13 21 603 Page 39 Figure 4 10 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE OR AUTO MODE EBH EBM EBP UNITS ONLY 227ECM797 B Ref Drawing...

Page 41: ...13 21 603 Page 40 Figure 4 11 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD EAH EAM EAP UNITS ONLY 214ECM797 B Ref Drawing...

Page 42: ...13 21 603 Page 41 Figure 4 12 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF EAH EAM EAP UNITS ONLY 215ECM797 B Ref Drawing...

Page 43: ...13 21 603 Page 42 Figure 4 13 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE SWITCH ON EAH EAM EAP UNITS ONLY 216ECM797 B Ref Drawing...

Page 44: ...13 21 603 Page 43 Figure 4 14 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 200 230 VOLT 60 75 HP 320EAM546 A Ref Drawing Page 1 of 2...

Page 45: ...13 21 603 Page 44 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 200 230 VOLT 60 75 HP 320EAM546 A Ref Drawing Page 2 of 2...

Page 46: ...13 21 603 Page 45 FIGURE 4 15 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 230 VOLT 60 HP 311EAM546 B Ref Drawing Page 1 of 2...

Page 47: ...13 21 603 Page 46 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 230 VOLT 60 HP 311EAM546 B Ref Drawing Page 2 of 2...

Page 48: ...13 21 603 Page 47 FIGURE 4 16 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 460 VOLT 60 75 100 HP 310EAM546 A Ref Drawing Page 1 of 2...

Page 49: ...13 21 603 Page 48 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 460 VOLT 60 75 100 HP 310EAM546 A Ref Drawing Page 2 of 2...

Page 50: ...13 21 603 Page 49 Figure 4 17 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 575 VOLT 100 HP 323EAM546 A Ref Drawing Page 1 of 2...

Page 51: ...13 21 603 Page 50 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 575 VOLT 100 HP 323EAM546 A Ref Drawing Page 2 of 2...

Page 52: ...13 21 603 Page 51 FIGURE 4 18 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 575 VOLT 60 75 HP 312EAM546 A Ref Drawing Page 1 of 2...

Page 53: ...13 21 603 Page 52 WIRING DIAGRAM WYE DELTA AIR COOLED WATER COOLED 575 VOLT 60 75 HP 312EAM546 A Ref Drawing Page 2 of 2...

Page 54: ...13 21 603 Page 53 FIGURE 4 19 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 200 230 VOLT 60 75 100 HP 322EAM546 A Ref Drawing Page 1 of 2...

Page 55: ...13 21 603 Page 54 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 200 230 VOLT 60 75 100 HP 322EAM546 A Ref Drawing Page 2 of 2...

Page 56: ...13 21 603 Page 55 FIGURE 4 20 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 460 VOLT 60 HP 313EAM546 C Ref Drawing Page 1 of 2...

Page 57: ...13 21 603 Page 56 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 460 VOLT 60 HP 313EAM546 C Ref Drawing Page 2 of 2...

Page 58: ...13 21 603 Page 57 FIGURE 4 21 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 460 VOLT 75 100 HP 321EAM546 A Ref Drawing Page 1 of 2...

Page 59: ...13 21 603 Page 58 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 460 VOLT 75 100 HP 321EAM546 A Ref Drawing Page 2 of 2...

Page 60: ...13 21 603 Page 59 FIGURE 4 22 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 575 VOLT 315EAM546 B Ref Drawing Page 1 of 2...

Page 61: ...13 21 603 Page 60 WIRING DIAGRAM FULL VOLT AIR COOLED WATER COOLED 575 VOLT 315EAM546 B Ref Drawing Page 2 of 2...

Page 62: ...13 21 603 Page 61 FIGURE 4 23 WIRING DIAGRAM LESS STARTER AIR COOLED WATER COOLED 200 230 460 VOLT 316EAM546 A Ref Drawing Page 1 of 2...

Page 63: ...13 21 603 Page 62 WIRING DIAGRAM LESS STARTER AIR COOLED WATER COOLED 200 230 460 VOLT 316EAM546 A Ref Drawing Page 2 of 2...

Page 64: ...13 21 603 Page 63 FIGURE 4 24 WIRING DIAGRAM LESS STARTER AIR COOLED WATER COOLED 575 VOLT 317EAM546 A Ref Drawing Page 1 of 2...

Page 65: ...13 21 603 Page 64 WIRING DIAGRAM LESS STARTER AIR COOLED WATER COOLED 575 VOLT 317EAM546 A Ref Drawing Page 2 of 2...

Page 66: ...rs 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 lubr...

Page 67: ...emperatures and pressures and 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...

Page 68: ...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 69: ...13 21 603 Page 68 Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM 221ECM797 B Ref Drawing...

Page 70: ...13 21 603 Page 69 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED COOLER 201EAP797 A Ref Drawing 218ECM797 A Ref Drawing...

Page 71: ...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 72: ...mer Service will include the filled out J214 form on any special orders sent to Engineering NOTICE When removing the cooling module from the package for remote operation the oil stop valve and the che...

Page 73: ...r leaks DO NOT OVERFILL The quantity required to raise the oil level from the red range center of the green range is shown in Figure 5 6 page 73 Repeated addition of oil between oil changes may indica...

Page 74: ...E 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 A...

Page 75: ...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 enough to us...

Page 76: ...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 77: ...or refer 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 Sh...

Page 78: ...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 79: ...ditions 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 engag...

Page 80: ...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 p...

Page 81: ...or 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...

Page 82: ...rator 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 83: ...g 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...

Page 84: ...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 Coo...

Page 85: ...zed 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 reinstall the filter element If the element r...

Page 86: ...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 element is below three 3 i...

Page 87: ...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 88: ...er 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 89: ...ic 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 a...

Page 90: ...e pressure and temperature 4 Check Panel LED s for advisories Every 125 Hours Operation 1 Check for dirt accumulation on oil aftercooler core faces and the cooling fan If cleaning is required clean th...

Page 91: ...y 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 92: ...tion 2 Blown fuse in starter control box 2 Replace fuse investigate if fuses continue to blow 3 Motor starter overload heaters trips 3 Reset and investigate cause of overload Compressor does not unloa...

Page 93: ...eaks 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 Excessive oil consumption 1 Oil...

Page 94: ...0 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 secti...

Page 95: ......

Page 96: ...For additional information contact your local representative or visit www contactgd com compressors 2014 Gardner Denver Inc Printed in U S A...

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