Gardner Denver ELECTRA-SAVER ETY99A Manual Download Page 8

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13–13–600 Page vii

LIST OF ILLUSTRATIONS

Figure #

Description

Page

Figure 1–1

Compression Cycle

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Figure 1–2

Air Cooled Unit – Less Enclosure – 1st Stage Compressor Side

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Figure 1–3

Air Cooled Unit – Less Enclosure – 2nd Stage Compressor Side

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Figure 1–4

Air Cooled Unit – Less Enclosure – Control Box End

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Figure 1–5

Air Cooled Unit – Less Enclosure – Oil Reservoir End

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Figure 2–1

Typical Compressor Room

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Figure 2–2

Air Flow Chart

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Figure 2–3

Piping Schematic

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Figure 2–4

Piping Diagram for Aftercooler and Heat Exchanger

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Figure 2–5

Cooler Drain Detail

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Figure 2–6

Cold Weather Installation

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Figure 2–7

Inlet Line Lengths

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Figure 2–8

Heat Exchanger (Oil Cooler) Approximate Water Flow

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Figure 2–9

Aftercooler Approximate Water Flow

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Figure 2–10

Ampacity, Fuse and Breaker Sizes

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Figure 4–1

Schematic Tubing Diagram

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Figure 4–2

Blowdown Valve

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Figure 4–3

Minimum Discharge Pressure Valve

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Figure 4–4

Inlet Valve

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Figure 4–5

Shuttle Valve

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Figure 4–6

Turn Valve Control

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Figure 4–7

Turn Valve Actuator

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Figure 4–8

Control Schematic – Compressor at Full Load

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Figure 4–9

Control Schematic – Compressor Fully Unloaded – Constant Speed Mode

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Figure 4–10

Control Schematic – Compressor Fully Unloaded – Low Demand Mode or Auto Mode

Figure 4–11

Wiring Diagram – 212EAP546

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Figure 5–1

Flow Diagram

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Figure 5–2

Oil Flow Diagram – Remote Overhead Mounted

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Figure 5–3

Oil Change Interval

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Figure 5–4

Approximate Oil System Capacities

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Figure 5–5

Water Control Valve

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Figure 5–6

Dew Point Temperature vs. Ambient Temperature, (100% Relative Humidity)

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Figure 5–7

Single Element Oil Separator

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Figure 6–1

Heavy Duty Air Filter (Standard)

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Figure 7–1

Installation of Coupling Cushions

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Summary of Contents for ELECTRA-SAVER ETY99A

Page 1: ...GARDNER DENVER ELECTRA SAVER TWO STAGE STATIONARY BASE MOUNTED COMPRESSOR AUTO SENTRY ES CONTROLS MODEL ETY99A 350 HP 500 HP OPERATING AND SERVICE MANUAL 13 13 600 1st Edition January 1998...

Page 2: ...er Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Machinery Inc Gardner Denver Machinery Inc Master Distribution Cen...

Page 3: ...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 injury death or substantial...

Page 4: ...ORDERING REPAIR PARTS When ordering parts specify Compressor MODEL Method of Cooling HORSEPOWER and SERIAL NUMBER see nameplate on unit The Serial Number is also stamped on top of the cylinder flange...

Page 5: ...ION 4 20 Controls Instruments General Description 20 Cooler Compressor Oil 36 Cooling Sealing and Lubrication 1 COUPLING SECTION 7 44 Coupling 44 Alignment 44 Individual Cushion Design 44 Daily Check...

Page 6: ...and Oil Discharge Temperature 41 Compressor Oil Inlet Temperature 41 Oil Cooler Oil Pressure Differential 41 Oil Cooler Temperature Differential 41 Oil Cooler Water Pressure Differential 41 Oil Inlet...

Page 7: ...ip 25 Thermal Control Thermostatic Mixing Valve 37 Thermistor Discharge 24 System 24 Transducer Reservoir Pressure 24 System Pressure 24 Transformer Control 25 TROUBLE SHOOTING SECTION 9 46 Tube Inlet...

Page 8: ...Ampacity Fuse and Breaker Sizes 15 Figure 4 1 Schematic Tubing Diagram 21 Figure 4 2 Blowdown Valve 22 Figure 4 3 Minimum Discharge Pressure Valve 22 Figure 4 4 Inlet Valve 23 Figure 4 5 Shuttle Valve...

Page 9: ...ve normal vol ume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of compression and seal internal clearances Volume re duction and pressure increase continues u...

Page 10: ...er toward the inlet end The valve opens and closes ports in the cylin der which communicates with the inlet passage This varies the compressor rotor volume to match the de mand for air thus reducing t...

Page 11: ...13 13 600 Page 3 FIGURE 1 4 AIR COOLED UNIT LESS ENCLOSURE CONTROL BOX END 300ETY797 Ref Drawing FIGURE 1 5 AIR COOLED UNIT LESS ENCLOSURE OIL RESERVOIR END 300ETY797 Ref Drawing...

Page 12: ...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 13: ...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 14: ...13 13 600 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 15: ...13 13 600 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 16: ...ighted well ventilated area with ample space all around for maintenance Select a location that provides a cool clean dry source of air In some cases it may be necessary to install the air filter at so...

Page 17: ...conveniently drain the oil some other methods of providing oil drain are 1 Elevate the compressor unit on a suitable struc ture to obtain the desired drain height 2 Construct an oil sump or trough bel...

Page 18: ...remote located on the same level as the compressor unit but some distance away S Overhead remote located above level of the compressor unit as on a roof The machine cannot be run blown down with remo...

Page 19: ...ses under spring load when the unit is shut down to prevent return oil flow from the oil cooler A different control group will be assembled onto the package to control the oil stop valve and to preven...

Page 20: ...ler location 3 Pipe type and size s to be used to connect the af tercooler separator and compressor unit mini mum pipe size is 5 NPT 4 Lengths of the pipe run If more than one pipe size is used list l...

Page 21: ...he oil reservoir and cooler during shutdown should be provided There are various methods to accomplish this but since openings are not provided for sump heaters the use of radiant heaters is recommend...

Page 22: ...If an Electra SaverR unit is manifolded to another com pressor be sure the other compressor has a check valve in the line between the machine and the manifold If an Electra SaverR and a reciprocating...

Page 23: ...m allowable water flow through the aftercooler is 70 gallons per minute on all 350 500 HP units Mini mum water pressure is 40 PSIG Maximum water pressure is 150 PSIG If another aftercooler is used con...

Page 24: ...nnection information Electrical shock can cause injury or death Open main disconnect switch tag and lockout before working on starter control box GROUNDING Equipment must be grounded in ac cordance wi...

Page 25: ...IUM R EXXON UNIREX 2 EXXON POLYREX Relubrication Type of Service Typical Examples Rating Interval Standard One or Two Shift Operation Above 150 HP 12 Months Severe Continuous Operation Above 150 HP 6...

Page 26: ...power may result in personal injury or death During unloaded operation and after shutdown the system will partially drain back into the oil res ervoir and the oil level may read higher than when oper...

Page 27: ...g starting procedures Unit Cold If the unit is a water cooled heat exchang er model open any manual water inlet valves wide open Start the unit by pushing either the CONSTANT RUN button or one of the...

Page 28: ...y time to stop the compressor under normal conditions Detailed instructions for the controller are found in the manual 13 9 10 647 Automatic restarting or electrical shock can cause injury or death Op...

Page 29: ...13 13 600 Page 21 FIGURE 4 1 SCHEMATIC TUBING DIAGRAM 302ETY797 A Ref Drawing...

Page 30: ...n the system pressure rises the spring is overridden and the valve opens to full porting The valve does not require maintenance or adjustment If the valve fails to function check the valve stem O ring...

Page 31: ...al discharge manifold to the compressor to counteract the oil knock that oc curs in oil flooded rotary screw compressors when they are completely unloaded with pressure in the oil reservoir This valve...

Page 32: ...use the keypad STOP RESET for normal controlled stopping Automatic restarting or electrical shock can cause injury or death Open tag and lockout main discon nect and any other circuits before servici...

Page 33: ...This provides connections for all 110 120 volt devices not contained within the enclo sure Fan Starter The starter is used to provide control and overload protection for the package fan Overload heate...

Page 34: ...13 13 600 Page 26 FIGURE 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 304ETY797 A Ref Drawing...

Page 35: ...13 13 600 Page 27 FIGURE 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED CONSTANT SPEED MODE 305ETY797 A Ref Drawing...

Page 36: ...13 13 600 Page 28 FIGURE 4 10 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE 306ETY797 A Ref Drawing...

Page 37: ...13 13 600 Page 29 FIGURE 4 11 WIRING DIAGRAM 302ETY546 Ref Drawing...

Page 38: ...use in rotary screw compressors AEON lu bricants are available through your authorized Gardner Denver compressor distributor OIL SPECIFICATIONS The factory fill compressor lubricant is Gardner Denver...

Page 39: ...13 13 600 Page 31 FIGURE 5 1 FLOW DIAGRAM 303ETY797 A Ref Drawing...

Page 40: ...13 13 600 Page 32 307ETY797 A Ref Drawing OIL PIPING FOR REMOTE COOLER FIGURE 5 2 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED...

Page 41: ...vel from the red range to the center of the green range is shown in FIGURE 5 4 page 35 Repeated addition of oil between oil changes may indicate exces sive oil carry over and should be investigated Ai...

Page 42: ...se 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 page 41 and Thermal Control Thermost...

Page 43: ...r plug 4 Remove the oil filler plug and add oil as required to return the oil level to the center of the green range on the gauge 5 Install the oil filler plug and operate the unit for about a minute...

Page 44: ...r from housing and remove 3 Screw new oil filter into housing 4 Run the unit and check for leaks BEARING OIL FILTER An oil filter of the spin on type is used This filter is a vital part in maintaining...

Page 45: ...rmal mixing valve as shown Modifications to the control lines will be made at the fac tory to control the oil stop valve Air to the oil stop valve must come from the dry side of the reservoir cover th...

Page 46: ...tain instances to inhibit corrosion and or remove dis solved solids to alter the water s tendency to form scale deposits or prevent the growth of microorgan isms The normal maintenance program for the...

Page 47: ...ional Equipment FIGURE 5 1 page 31 A magnetic solenoid oper ated water shutoff valve rated at 150 psig 10 3 Bars water pressure should be mounted in the water outlet line after the oil cooler The valv...

Page 48: ...re differential gauging or by in spection Pressure Differential Gauging The CHANGE SEPARATOR advisory will flash when the pressure differential across the oil separator reaches approxi mately 8 PSID 5...

Page 49: ...C Install a tee at the oil filter outlet and check with a thermometer Oil Inlet Pressure Check at the fitting in the line near the compressor oil inlet With air receiver pressure at 100 psi 6 9 Bar oi...

Page 50: ...arm water with a mild nonsudsing detergent Rinse the element thoroughly with clean water a hose may be used if the water pressure does not exceed 40 psig 2 8 Bars 4 Inspect the element for ruptures or...

Page 51: ...ect the inlet screen and tube for dirt accumulation each time the filter is serviced Clean the tube when required by ramming a clean dry cloth through the tube Wipe the inside of the filter body to re...

Page 52: ...sure the collar is installed on the shaft behind one coupling body 2 Assemble the motor to the compressor 3 Working through the coupling guard opening cen ter the coupling over the gap between the sh...

Page 53: ...core faces and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed air carrying a nonflammable safety solvent in a direction opposite that of th...

Page 54: ...ps after a short time Air Temperature this section page 47 2 High discharge 2 Replace switch temperature switch malfunction 3 Blown fuse in starter 3 Replace fuse control box investigate if fuses cont...

Page 55: ...er or clean cooler interior cooler 5 Low compressor oil 5 Add oil to proper level Excessive Oil Consumption 1 Oil carryover through lines 1 See Oil Carryover below 2 Oil leaks at all fittings 2 Tighte...

Page 56: ...eration at elevated 7 Reduce temperature See discharge temperatures High Discharge Air Temperature page 47 this section 8 Scavenge line check 8 Replace check valve valve failure 9 Water condensate in...

Page 57: ...gment is proved not to be as warranted Labor shall be limited to the amount specified in the Company s labor rate schedule Labor costs in excess of the Company rate schedule amounts or labor provided...

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