Gardner Denver ELECTRA-SAVER EAQ99Q Operating And Service Manual Download

Page: 1 / 76

GARDNER DENVER

13-9-666

Version: 01

November 14, 2003

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)

OPERATING AND

SERVICE MANUAL

Summary of Contents for ELECTRA-SAVER EAQ99Q

Page 1: ...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...

Page 2: ...thorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact Distribution Center Factory Gardner Denver Master Distribution Center 5585 East Shelby D...

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

Page 4: ...ed Airends ii Foreword iii Index v List Of Illustrations vii Section 1 General Information 1 Section 2 Installation 8 Section 3 Starting Operating Procedures 19 Section 4 Controls Instrumentation 22 S...

Page 5: ...Oil Piping 46 High Temperature Operation 41 Inlet Line 12 Inlet Screen And Tube 59 Inlet Valve 25 Installation General 8 Installation For Cold Weather Operation 11 Installation Section 2 8 Lifting Uni...

Page 6: ...ection 8 Maintenance Schedule 63 Section 9 Troubleshooting 65 Series Piping 16 Service Check List 63 Every 1000 Hours Operation 63 Every 125 Hours Operation 63 Every 8 Hours Operation 63 Every 8000 Ho...

Page 7: ...l Schematic Compressor At Full Load Constant Speed Mode 31 Figure 4 9 Control Schematic Compressor Unloaded Low Demand Mode Or Auto Mode 32 Figure 4 10 Control Schematic Compressor At Full Load 33 Fig...

Page 8: ...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 9: ...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 10: ...13 9 666 Page 3 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 200EDM797 A Ref Drawing...

Page 11: ...13 9 666 Page 4 Figure 1 6 AIR OIL FLOW DIAGRAM 202EDM797 Ref Drawing...

Page 12: ...in accordance with the National Electrical Code NFPA 70 and any applicable local electrical codes Wiring and electrical service must be performed only by qualified electricians Open main disconnect sw...

Page 13: ...13 9 666 Page 6 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077...

Page 14: ...13 9 666 Page 7 DECALS 216EAQ077 217EAQ077 222EAQ077 221EAQ077 208EAQ077...

Page 15: ...e motor only and should not be used to lift any additional weight All eyebolts must be securely tightened When lifting the motor the lifting angle must not exceed 15 degrees Failure to observe this wa...

Page 16: ...igure 2 2 AIR FLOW CHART WARNING These compressors have aluminum oil coolers do not use any cleaning solution that is not compatible with aluminum Use of improper solution may result in damage to the...

Page 17: ...and the base bottom must be closed with solid material all around to prevent recirculation of hot air from the oil cooler end and over temperature operation ENCLOSURE The compressor electric motor oil...

Page 18: ...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 19: ...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 20: ...will cause 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 pipe...

Page 21: ...F 90 F 125 HP EAQ99Q 2 1 2 6 3 4 5 2 55 125 HP EBQ99M 2 1 2 6 3 4 5 2 55 150 HP EAQ99Q 2 7 3 3 4 5 6 7 55 150 HP EBQ99M 2 7 3 3 4 5 6 7 55 200 HP EAQ99Q 3 6 4 5 6 0 9 0 90 200 HP EAU99Q 3 6 4 5 6 0 9...

Page 22: ...water flow 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...

Page 23: ...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 24: ...e the starter is too large to be mounted within the control enclosure If not supplied with the compressor unit the starter must be a size 6 full voltage non reversing type in NEMA CEMA enclosure suita...

Page 25: ...tating machinery can cause injury or death Open main disconnect lockout and tagout power supply to starter before working on the electric motor ELECTRIC MOTOR GREASE RECOMMENDATIONS 30 C to 50 C MANUF...

Page 26: ...tervals of AEON 9000 SP synthetic lubricant Use only genuine Gardner Denver filters designed and specified for this compressor DANGER Before removing the oil filler plug always stop the unit and relea...

Page 27: ...ed WARNING The compressor unit s direction of rotation must be checked every time the compressor is reconnected to the power supply 8 System Pressure Set the controls to the desired load pressure DO N...

Page 28: ...he AUTO 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 re...

Page 29: ...manual 13 9 653 WARNING Automatic restarting or electrical shock can cause injury or death Disconnect lockout and tagout the unit from the power supply and any other circuits before servicing unit CO...

Page 30: ...o not plug vent or restrict discharge WARNING Operation of the unit with improper relief valve setting can result in severe personal injury or machine damage Ensure properly set valves are installed a...

Page 31: ...provided to ensure that the inlet valve is closed during blowdown Oil Level Gauge Figure 1 6 page 4 This gauge is located on the oil reservoir and indicates the oil level See Section 5 for information...

Page 32: ...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 33: ...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 34: ...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 35: ...table 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 informatio...

Page 36: ...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 37: ...13 9 666 Page 30 Figure 4 7 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE EBQ EBU UNITS ONLY 209EDM797 A Ref Drawing...

Page 38: ...13 9 666 Page 31 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE EBQ EBU UNITS ONLY 211EDM797 A Ref Drawing...

Page 39: ...13 9 666 Page 32 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE OR AUTO MODE EBQ EBU UNITS ONLY 213EDM797 A Ref Drawing...

Page 40: ...13 9 666 Page 33 Figure 4 10 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD EAQ EAU UNITS ONLY 210EDM797 A Ref Drawing...

Page 41: ...13 9 666 Page 34 Figure 4 11 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF EAQ EAU UNITS ONLY 212EDM797 A Ref Drawing...

Page 42: ...13 9 666 Page 35 Figure 4 12 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE SWITCH ON EAQ EAU UNITS ONLY 214EDM797 A Ref Drawing...

Page 43: ...13 9 666 Page 36 Figure 4 13 WIRING DIAGRAM WYE DELTA EBQ EBU UNITS 300EDM546 A Ref Drawing...

Page 44: ...13 9 666 Page 37 Figure 4 14 WIRING DIAGRAM FULL VOLTAGE EBQ EBU UNITS...

Page 45: ...13 9 666 Page 38 Figure 4 15 WIRING DIAGRAM WYE DELTA EAQ EAU UNITS ONLY 301EAQ546 B Ref Drawing...

Page 46: ...13 9 666 Page 39 Figure 4 16 WIRING DIAGRAM FULL VOLTAGE EAQ EAU UNITS ONLY 303EAQ546 Ref Drawing...

Page 47: ...e lubricants are formulated to the highest quality standards and are factory authorized tested and approved for use in rotary screw compressors AEON lubricants are available through your authorized Ga...

Page 48: ...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 cycles high humidity gross...

Page 49: ...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 50: ...13 9 666 Page 43 Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM 203EDM797 A Ref Drawing...

Page 51: ...13 9 666 Page 44 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED COOLER 204EAQ797 A Ref Drawing 205EDM797 Ref Drawing...

Page 52: ...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 bodi...

Page 53: ...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 54: ...green range is shown in Figure 5 6 page 48 Repeated addition of oil between oil changes may indicate excessive oil carryover and should be investigated DANGER Air oil under pressure will cause severe...

Page 55: ...Figure 1 6 page 4 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 56: ...ways drain 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 el...

Page 57: ...f necessary 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...

Page 58: ...olts and filters DANGER Compressor air oil reservoir separation chamber and all piping and tubing may be at high temperature during and after operation Use the following procedure to replace the filte...

Page 59: ...he 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 of...

Page 60: ...conditions 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 en...

Page 61: ...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 62: ...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 63: ...ain unit is completely off 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 L...

Page 64: ...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 65: ...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 66: ...on hand 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...

Page 67: ...ath 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...

Page 68: ...oupling lock all set screws to 50 ft lbs If element is not centered unlock set screws and slide coupling to center element between shaft ends and then using the loctite supplied with the coupling lock...

Page 69: ...pplied to set screws to 50 ft lbs If element is not centered unlock the set screws and slide coupling to center element between shaft ends and then using the loctite supplied with the coupling lock al...

Page 70: ...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 71: ...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 72: ...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 73: ...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 74: ...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 75: ...initial use or 15 months from date of shipment to first purchaser whichever occurs first LABOR TRANSPORTATION AND INSPECTION The Company will provide labor by Company representative or authorized ser...

Page 76: ...rvice Department Telephone 800 682 9868 FAX 217 224 7814 Sales and Service in all major cities For parts information contact Gardner Denver Master Distribution Center Memphis TN Telephone 800 245 4946...

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