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13-21-608

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September 7, 2018

ELECTRA-SAVER

ELECTRA-SAVER II

STATIONARY BASE-MOUNTED

COMPRESSOR

AirSmart™ CONTROLLER

DOMESTIC and INTERNATIONAL MODELS

EAQ99W – 125, 150, and 200 HP, 60 HZ

EBQ99R – 125, 150, and 200 HP, 60 HZ

EAU99AB – 200 HP, 60 HZ

EBU99H – 200 HP, 60 HZ

EAQ99W – 100, 125, and 150 HP, 50 HZ
(75, 93, 112 KW)

EBQ99R – 125 and 150 HP,

(93, 112 KW) 50 HZ

EAU99AB – 200 HP, (150 KW) 50 HZ

EBU99H – 200 HP, (150 KW) 50 HZ

OPERATING AND

SERVICE MANUAL

Содержание AirSmart ELECTRA-SAVER

Страница 1: ...NTROLLER DOMESTIC and INTERNATIONAL MODELS EAQ99W 125 150 and 200 HP 60 HZ EBQ99R 125 150 and 200 HP 60 HZ EAU99AB 200 HP 60 HZ EBU99H 200 HP 60 HZ EAQ99W 100 125 and 150 HP 50 HZ 75 93 112 KW EBQ99R...

Страница 2: ...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 assist you by provid...

Страница 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...

Страница 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...

Страница 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...

Страница 6: ...ion 7 Coupling 69 Section 8 Maintenance Schedule 72 Section 9 Troubleshooting 74 This book covers the following models HP KW PSIG Model Parts List Controller Manual Comm Module Manual 125 150 200 HP 6...

Страница 7: ...ing 54 High Temperature Operation 49 Inlet Line 17 Inlet Screen And Tube 67 Inlet Valve 33 Installation For Cold Weather Operation 16 Installation Section 2 13 Lifting Unit 13 Location 14 Air Cooled U...

Страница 8: ...ction 9 Troubleshooting 73 Series Piping 21 Service Check List 71 Every 125 Hours Operation 71 Every Year 71 Motor Lubrication 71 Oil Separator 71 Service Check List Air Filter 71 Shuttle Valve 34 Sol...

Страница 9: ...ssor Unloaded Constant Speed Mode 38 Figure 4 9 Control Schematic Compressor At Full Load Constant Speed Mode 39 Figure 4 10 Control Schematic Compressor Unloaded Low Demand Mode Or Auto Mode 40 Figur...

Страница 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...

Страница 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...

Страница 12: ...13 21 608 Page 11 Figure 1 4 COMPRESSOR MOTOR SIDE Figure 1 5 COOLER RESERVOIR SIDE 200EDM797 A Ref Drawing...

Страница 13: ...13 21 608 Page 12 Figure 1 6 AIR OIL FLOW DIAGRAM 202EDM797 Ref Drawing...

Страница 14: ...may also be moved into location by rolling on bars Lift compressor package by base only Do not use other places such as motors compressors or discharge manifold piping as lifting points The eyebolts...

Страница 15: ...ent on all air cooled units The air cooled unit with the standard enclosure requires sufficient flow Figure 2 2 for the compressor oil aftercooling system and for electric motor cooling Air is drawn i...

Страница 16: ...lts and shims to provide uniform support for the base OIL RESERVOIR DRAIN The oil drain is piped from the bottom of the reservoir to the side of the frame This drain is approximately 4 50 inches 115 m...

Страница 17: ...ust be made the precautions required will depend on the severity of the environment The following are general guidelines for outside installations Cold Weather Down To 10 F 12 C 1 Be sure all drains t...

Страница 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...

Страница 19: ...e 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 piped back int...

Страница 20: ...25 HP EAQ99W 1 9 2 4 3 2 4 8 55 Less than 1 PSI for any flow rate shown in the table 125 HP EBQ99R 1 8 2 2 3 0 4 5 55 150 HP EAQ99W 2 3 2 9 3 9 5 8 55 150 HP EBQ99R 2 1 2 6 3 4 5 2 55 200 HP EAQ99W 2...

Страница 21: ...ter 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 60...

Страница 22: ...PING 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...

Страница 23: ...est obstruction on starter and control box sides of the unit Lower operating voltages 200 208 require that the unit starter be remote mounted since the starter is too large to be mounted within the co...

Страница 24: ...t 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 lockout...

Страница 25: ...pressure See Figure 5 7 page 58 NOTICE Regular maintenance and replacement at required intervals of the oil filter air filter and air oil separator is necessary to achieve maximum service and extende...

Страница 26: ...rotation can damage equipment and cause oil eruption from the compressor inlet When checking motor rotation induce minimum rotation less than one revolution if possible Never allow motor to reach ful...

Страница 27: ...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 requi...

Страница 28: ...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...

Страница 29: ...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...

Страница 30: ...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...

Страница 31: ...test the relief valve 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...

Страница 32: ...ation 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...

Страница 33: ...is provided 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 inform...

Страница 34: ...mum 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 body Th...

Страница 35: ...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...

Страница 36: ...ot 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 cont...

Страница 37: ...mers employed are usually connectable for several input voltages refer to transformer label for connection prior to energizing Two primary and one secondary fuse are provided Refer to adjacent labelin...

Страница 38: ...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...

Страница 39: ...13 21 608 Page 38 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR UNLOADED CONSTANT SPEED MODE EBQ EBU UNITS ONLY 209EDM797 A Ref Drawing...

Страница 40: ...13 21 608 Page 39 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD CONSTANT SPEED MODE EBQ EBU UNITS ONLY 211EDM797 A Ref Drawing...

Страница 41: ...13 21 608 Page 40 Figure 4 10 CONTROL SCHEMATIC COMPRESSOR UNLOADED LOW DEMAND MODE OR AUTO MODE EBQ EBU UNITS ONLY 213EDM797 A Ref Drawing...

Страница 42: ...13 21 608 Page 41 Figure 4 11 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD EAQ EAU UNITS ONLY 210EDM797 A Ref Drawing...

Страница 43: ...13 21 608 Page 42 Figure 4 12 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF EAQ EAU UNITS ONLY 212EDM797 A Ref Drawing...

Страница 44: ...13 21 608 Page 43 Figure 4 13 CONTROL SCHEMATIC COMPRESSOR FULLY LOADED LOW DEMAND MODE SWITCH ON EAQ EAU UNITS ONLY 214EDM797 A Ref Drawing...

Страница 45: ...13 21 608 Page 44 Figure 4 14 WIRING DIAGRAM WYE DELTA 335EAQ546 A Ref Drawing Page 1 of 2...

Страница 46: ...13 21 608 Page 45 335EAQ546 A Ref Drawing Page 2 of 2...

Страница 47: ...13 21 608 Page 46 Figure 4 15 WIRING DIAGRAM LESS STARTER 336EAQ546 A Ref Drawing Page 1 of 3...

Страница 48: ...13 21 608 Page 47 336EAQ546 A Ref Drawing Page 2 of 3...

Страница 49: ...13 21 608 Page 48 336EAQ546 A Ref Drawing Page 3 of 3...

Страница 50: ...nts These 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 autho...

Страница 51: ...he 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 thermal mixing...

Страница 52: ...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...

Страница 53: ...13 21 608 Page 52 Figure 5 3 FLOW DIAGRAM AIR OIL SYSTEM 203EDM797 A Ref Drawing...

Страница 54: ...13 21 608 Page 53 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED COOLER 204EAQ797 A Ref Drawing 205EDM797 Ref Drawing...

Страница 55: ...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...

Страница 56: ...ing 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 sho...

Страница 57: ...nter of the green range is shown in Figure 5 6 page 57 Repeated addition of oil between oil changes may indicate excessive oil carryover and should be investigated Air oil under pressure will cause se...

Страница 58: ...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...

Страница 59: ...rain 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 elevated...

Страница 60: ...if 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 FUL...

Страница 61: ...ut and tagout power supply to the starter before removing valves caps plugs fittings bolts and filters Compressor air oil reservoir separation chamber and all piping and tubing may be at high temperat...

Страница 62: ...r cooled radiator and water cooled heat exchanger type oil cooler systems On start up with unit cold element is open to bypass allowing oil to pass directly from the reservoir to compressor during war...

Страница 63: ...can cause scale formation corrosion and plugging of any water cooled heat exchanger equipment Disregarding the possibility that one or more of these conditions exist may result in increased maintenan...

Страница 64: ...ube 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...

Страница 65: ...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...

Страница 66: ...t 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 Lift the...

Страница 67: ...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...

Страница 68: ...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...

Страница 69: ...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 if...

Страница 70: ...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...

Страница 71: ...sher 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...

Страница 72: ...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...

Страница 73: ...5 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 accumu...

Страница 74: ...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...

Страница 75: ...arge 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 investig...

Страница 76: ...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 17 600 Excessive oil co...

Страница 77: ...9000SP 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 sec...

Страница 78: ......

Страница 79: ...NOTES...

Страница 80: ...For additional information contact your local representative or visit www contactgd com compressors 2018 Gardner Denver Inc Printed in U S A...

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