Gardner Denver ELECTRA-SAVER EAU PD - 200 HP Operating And Service Manual Download Page 1

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GARDNER DENVER

ELECTRA–SAVER

STATIONARY SCREW

COMPRESSOR

With AUTO SENTRY

–ES CONTROLLER

MODELS

EAU_PD – 200 HP

EAU_QD – 250 HP

EAU_RD – 300 HP

OPERATING AND
SERVICE MANUAL

13–10–612

1st Edition

August, 1994

Summary of Contents for ELECTRA-SAVER EAU PD - 200 HP

Page 1: ...GARDNER DENVER ELECTRA SAVER STATIONARY SCREW COMPRESSOR With AUTO SENTRY ES CONTROLLER MODELS EAU_PD 200 HP EAU_QD 250 HP EAU_RD 300 HP OPERATING AND SERVICE MANUAL 13 10 612 1st Edition August 1994...

Page 2: ...ion of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Machinery Inc Gardner Den...

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

Page 4: ...1 INSTALLATION SECTION 2 STARTING AND OPERATING PROCEDURES SECTION 3 CONTROLS AND INSTRUMENTS SECTION 4 LUBRICATION OIL COOLER OIL FILTER AND SEPARATOR SECTION 5 AIR FILTERS SECTION 6 BELT DRIVE SECT...

Page 5: ...ter Element 47 Filter Element Life 48 Inlet Screen and Tube 48 AIR FILTERS SECTION 6 48 Air Flow 1 Compression Principle 1 Air Receiver Auxiliary 10 Air Cooled Machine Aftercooler 10 Air Cooled Oil Co...

Page 6: ...HP Units 47 Compressor Oil 37 Filter Element 45 Filter Element Life 45 Foreward ii Foundation 8 Gauge Oil Level 37 Gauges and Displays 22 Oil Filter Indicator 22 Oil Level 22 GENERAL INFORMATION SECT...

Page 7: ...il System Check 43 Air and Oil Discharge Temperature 43 Oil Cooler Oil Pressure Differential Air Cooled Radiator 44 Oil Cooler Oil Pressure Differential Water Cooled Heat Exchanger 44 Oil Cooler Press...

Page 8: ...HECK LIST AIR FILTER 50 Service Check List 50 Every 1000 Hours Operation 50 Every 125 Hours Operation 50 Every 6000 Hours Operation 50 Every 8 Hours Operation 50 Every Year 50 Motor Lubrication 50 Oil...

Page 9: ...2 Ventilation 8 Ventilation Oil Cooler Module 9 Vibration Switch 25 Water Flow Control Valve for Heat Exchanger 41 Water Piping Water Cooled Heat Exchanger 13 Water Piping Aftercooler Heat Exchanger 1...

Page 10: ...4 4 Shuttle Valve 23 Figure 4 5 Turn Valve 24 Figure 4 6 Minimum Discharge Pressure Valve Older Models 24 Figure 4 7 Minimum Discharge Pressure Valve Current Models 24 Figure 4 8 Control Schematic Com...

Page 11: ...l volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of com pression and seal internal clearances Volume reduc tion and pressure increase continues until the...

Page 12: ...13 10 612 Page 2 FIGURE 1 2 PACKAGE UNIT WITH WATER COOLED AFTERCOOLER FIGURE 1 3 PACKAGE UNIT WITH WATER COOLED AFTERCOOLER...

Page 13: ...13 10 612 Page 3 FIGURE 1 4 STARTER BOX FIGURE 1 5 PACKAGE CONTROLLER AND STARTERS...

Page 14: ...plug drain plugs covers the thermostat ic mixing valve or break any connections etc in the compressor air or oil sys tem until the unit is shut down and the air pressure has been relieved D Electrical...

Page 15: ...and lockout be fore working on the unit this machine is automatically controlled and may start at any time D An Excess Flow Valve should be on all compressed air supply hoses ex ceeding 1 2 inch insid...

Page 16: ...13 10 612 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 17: ...13 10 612 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 18: ...ooling air as well as air to the compressor inlet Proper ventilation MUST be provided FIGURE 2 2 hot air must be ex hausted from compressor operating area A typical in let outlet air flow arrangement...

Page 19: ...and General Piping The oil cooler module can be mounted in any of several remote locations close coupled but not joined to the compres sor unit horizontal remote located on the same level as the compr...

Page 20: ...cs 3 Select properly tensioned and aligned piping sup port clamps or hangers and position them to re lieve any piping stress at the oil cooler inlet and outlet ports Do not support from flexible conne...

Page 21: ...ted to temperatures above freezing 32_ F 0_ C This will eliminate many of the problems associated with operat ing the units outside in cold climates where freezing rain drifting snow freezing condensa...

Page 22: ...methods to accomplish this but since openings are not provided for sump heaters the use of radiant heaters is recommended Heat ers should be sized to provide at least a 10_ F environment for the coole...

Page 23: ...ation DISCHARGE SERVICE LINE The discharge service line connection on water cooled units with aftercooler is made at the moisture separator On air cooled units and water cooled without aftercooler the...

Page 24: ...tercooler is piped in series with the oil cooler the maximum al lowable water flow rate through the oil aftercooler system is the maxi mum allowed by the aftercooler If the oil cooler requires more wa...

Page 25: ...connect 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 Rotating machinery can cause injury or death Open main disconnect ta...

Page 26: ...n back into the oil reservoir and the oil level will read higher than when operating on load DO NOT DRAIN OIL TO CORRECT on the next loaded cycle or start oil will again fill the system and the gauge...

Page 27: ...eservoir will automatically blow down as the motor stops If the unit is a water cooled heat ex changer type close any manual water inlet valves SEQUENCING COMPRESSORS Sequencing compressors with the A...

Page 28: ...hey are also capable of delivering air at a pressure determined by the above formula To insure that two or more machines do not simulta neously decrement their rotation numbers and simulta neously bec...

Page 29: ...otation it will automatically close the gap by decrementing the rotation numbers of all compressors whose rotation numbers were greater than the missing number Like wise if for whatever reason the mas...

Page 30: ...y provide the operator with a logical and easily operated control of the compressor and indication of its condition PROTECTIVE DEVICES ADVISORIES AND SHUT DOWNS The AUTO SENTRY ES will shut down the u...

Page 31: ...ator Differential Pressure The separator dif ferential pressure is continually monitored by the Auto Sentry ES At a differential pressure of approximately 15 psi the unit will be shut down High Pressu...

Page 32: ...unit if abnormally high vibration is de tected Check CN 7 8 9 This indicates a wiring error or con nection problem Remove power and correct all wiring Blowdown Valve FIGURE 4 3 The blowdown so lenoid...

Page 33: ...lve from slamming The regulator should be set for 25 30 psig Shuttle Valve FIGURE 4 4 Also known as a double check valve the shuttle valve is a device which will take two 2 supply signals and allow th...

Page 34: ...tion The rod must be clean and free of burrs and scale Take care not to scrape the cylinder walls when moving the pistons FIGURE 4 6 MINIMUM DISCHARGE PRESSURE VALVE OLDER MODELS Minimum Discharge Pre...

Page 35: ...essor unit Its dis play provides all gauging functions shutdown causes and maintenance recommendations The keypad pro vides the user with selection of operating modes and adjustment to tune the contro...

Page 36: ...time delay is adjustable from 5 to 30 minutes If the controller operates unloaded for this period with no demand the compressor drive motor is halted to eliminate its power consumption The controls w...

Page 37: ...while the bottom line shows the variable that is capable of being altered by programming The following is a step by step guide to programing the AUTO SENTRY ES Controller Between each key it is necess...

Page 38: ...spends in the start mode It should be set to transfer the starter to the run mode as soon as the motor reaches its maximum attainable speed in the start mode If the set switch is off the con trol retu...

Page 39: ...as is appropriate for the compressor 21 In the top line SYSTEM VOLUME is displayed The bottom line may be selected as SMALL ME DIUM or LARGE This tunes the response of the modulation control loops to...

Page 40: ...13 10 612 Page 30 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 214ECM797 Ref Drawing...

Page 41: ...13 10 612 Page 31 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE 216ECM797 Ref Drawing...

Page 42: ...13 10 612 Page 32 FIGURE 4 10 WIRING DIAGRAM 212EAP546 Ref Drawing...

Page 43: ...13 10 612 Page 33 FIGURE 4 11 AUTO SENTRY ES CONTROLLER DISPLAY...

Page 44: ...ardner Denver compressors Use of improper lubricants will cause damage to equipment Do not mix dif ferent types of lubricants or use infe rior lubricants HIGH TEMPERATURE OPERATION If the dis charge t...

Page 45: ...13 10 612 Page 35 FIGURE 5 1 FLOW DIAGRAM AIR OIL SYSTEM 215EAU797 Ref Drawing...

Page 46: ...ized Gardner Denver distributor or by calling the factory at 217 222 5400 COLD AMBIENT OPERATION See Installation for Cold Weather Operation Section 2 page 11 ADDITION OF OIL BETWEEN CHANGES must be m...

Page 47: ...ressor lubrication and could cause oil carryover If moisture is observed in the oil reservoir drain the moisture and correct the condition causing the accumulation See Compressor Oil System Check and...

Page 48: ...e as oil fills other areas of the system 5 Shut down unit allowing the oil to settle and be certain all pressure is relieved 6 Add oil if necessary to bring the level to the RUN range On unloaded oper...

Page 49: ...ct ing piping and wiring are furnished by the user See Installation Section 2 page 8 Do not obstruct the air flow to and from the oil cooler Allow two 2 feet clearance on all sides of the oil cooler S...

Page 50: ...HERMAL CONTROL THERMOSTATIC MIXING VALVE FIGURE 5 5 on current units is installed in the system as shown in FIGURE 5 1 page 35 On early units this valve is in the line between the reservoir and cooler...

Page 51: ...ds may be necessary in certain instances to in hibit corrosion and or remove suspended solids to alter the water s tendency to form scale deposits or prevent growth of microorganisms The normal mainte...

Page 52: ...tical section of the oil reservoir consists of a single high efficiency pleated element and provides the final re moval of oil from the air stream Oil from inside the sep arator element is returned th...

Page 53: ...l reservoir 11 Seat the top plate to the oil reservoir flange install and tighten all cap screws 12 Reconnect the discharge manifold pipe union and all tubing 13 Install the original oil return by sli...

Page 54: ...re Differential Air Cooled Radiator 2 to 25 PSI 65 to 150 PSIG Receiver Pres sure Check at the fitting in the inlet and outlet lines of the oil cooler Oil Cooler Oil Pressure Differential Water Cooled...

Page 55: ...up and down the pleat slowly moving across the face of the element Nozzle must be kept at least one inch away from the element Take care the paper is not ruptured by the nozzle or air jet When cleani...

Page 56: ...t thoroughly with clean water a hose may be used if the water pressure does not exceed 40 PSIG 4 Inspect the element for ruptures or cracks in the pleated media replace the element if any are found In...

Page 57: ...ge replace parts as required Install the dust cup with port in the baffle up and make sure clamping is secure and posi tioned properly to prevent leakage Filter Element Service the air filter element...

Page 58: ...lable through your authorized Gardner Denver distributor Filter Element Life The element should be replaced after six cleanings or if 1 Visual inspection indicated a rupture crack or pin hole in the p...

Page 59: ...e collar is installed on the shaft behind one coupling body 2 Assemble the motor to the compressor 3 Working through coverplate opening center cou pling over the gap between the shafts maintaining the...

Page 60: ...g fan If cleaning is required clean the exterior fin surfaces of the cores by blow ing compressed air carrying a nonflammable safety solvent in a direction opposite that of the cooling fan air flow Th...

Page 61: ...pressor starts but 1 High discharge temperature 1 See High Discharge stops after a short time Air Temperature page 2 this section 2 High discharge 2 Replace switch temperature switch malfunction 3 Blo...

Page 62: ...inimum pressure valve 4 Disassemble and clean stuck closed valve 5 Turn valve adjustment or 5 Adjust turn valve per or malfunction Section 4 High discharge air 1 Thermostatic mixing 1 Repair or replac...

Page 63: ...Ruptured oil separator 3 Replace element element 4 Loose assembly 4 Tighten all fittings and gaskets 5 Foam caused by use of 5 Use Gardner Denver incorrect oil AEON 4000 or 9000 SP Lubricating Coolan...

Page 64: ...if the receiver or air end discharge is less than 40_ F 4 4_ C Refer to corrective measures for low ambient conditions in the Operator s Manual See Section 2 Page 2 HIGH TEMPERATURE The advisory comes...

Page 65: ......

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