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Содержание AUTO SENTRY EAU99P

Страница 1: ...ersion 03 July 31 2009 ELECTRA SAVER STATIONARY BASE MOUNTED COMPRESSOR AUTO SENTRY ES CONTROLS DOMESTIC MODELS EAU99P 200 250 300 HP INTERNATIONAL MODELS EAU99R EAU99S 150 186 225 KW OPERATING AND SERVICE MANUAL ...

Страница 2: ...formulated for use in Gardner Denver compressors 4 Repair and maintenance kits designed with the 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 assist you by providing fast expert maintenance and repair services For the location of your local authoriz...

Страница 3: ...omical 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 areas of the compressor package to alert users of the following conditions Indicates a hazard with a high level of risk which if not avoided WILL result in death or serious injury Equipment starts au...

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 Lift Equipment with Hook No Lift Point Handle Package at Forklift Points Only Lockout Electrical Equipment in De Energized State Loud Noise Hazard Wear Ear Protection Read the Operator s Manual Before ...

Страница 5: ...or 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 applicable local electrical codes Wiring and electrical service must be performed only by qualified electricians Open main disconnect switch lockout and tagout before working on the control wait 10 ...

Страница 6: ...ion 13 Section 3 Starting Operating Procedures 24 Section 4 Controls Instrumentation 27 Section 5 Lubrication Oil Cooler Oil Filter Separator 40 Section 6 Air Filter 60 Section 7 Coupling 62 Section 8 Maintenance Schedule 65 Section 9 Troubleshooting 67 This book covers the following models HP PSIG Model Parts List Controller Manual 200 250 300 100 125 150 EAU99P 13 10 519 13 9 653 HP Kw PSIG bar ...

Страница 7: ...cant Change Procedure 48 Lubrication Motor 22 Lubrication Cooling And Sealing 10 Lubrication Section 5 40 Maintenance Schedule Section 8 65 Moisture Separator Trap 17 Motor Lubrication 22 Oil Change Interval 49 Oil Cooler Compressor 53 Oil Level Gauge 49 Oil Reservoir 56 Oil Reservoir Drain 15 Oil Separator Compressor Gd Eliminator 57 Inspection 57 Oil Carryover 57 Removal For Inspection Or Replac...

Страница 8: ... Section 3 24 Starting The Unit 26 Unit Cold 26 Unit Hot 26 Stopping The Unit 26 Thermal Control Thermostatic Mixing Valve 54 Troubleshooting Section 9 67 Turn Valve 10 Warning Prohibition Mandatory Label Information 2 Water Flow Control Valve For Heat Exchanger 55 Water Piping 20 Water Shutoff Valve Water Cooled Heat Exchanger 56 Water Cooled Units Location 14 ...

Страница 9: ...e 30 Figure 4 5 Shuttle Valve 31 Figure 4 6 Turn Valve Actuator Sectioned 31 Figure 4 7 Control Schematic Compressor At Full Load 34 Figure 4 8 Control Schematic Compressor Fully Unloaded Low Demand Mode Switch Off 35 Figure 4 9 Control Schematic Compressor Fully Unloaded Low Demand Mode Switch On 36 Figure 4 10 Wiring Diagram Wye Delta ES Controller Air Cooled 37 Figure 4 11 Wiring Diagram Wye De...

Страница 10: ... air 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 meshing rotors B As meshing continues more of the main rotor lobe enters the secondary rotor grove normal volume is reduced and pressure increases Oil is injected into the cylinder to remove the heat of...

Страница 11: ...il is injected directly into the compression chamber to remove heat of compression seal internal clearances and lubricate the rotors TURN VALVE The turn valve is a rotary helical valve located on the discharge side of the cylinder toward the inlet end The valve opens and closes ports in the cylinder which communicates with the inlet passage This varies the compressor rotor volume to match the dema...

Страница 12: ...13 10 615 Page 11 Figure 1 4 PACKAGE DRIVE MOTOR AIR FILTER Figure 1 5 PACKAGE OIL FILTER OIL LEVEL GAUGE MIXING VALVE MINIMUM PRESSURE VALVE CHECK VALVE 201EAU797 Ref Drawing 201EAU797 Ref Drawing ...

Страница 13: ...13 10 615 Page 12 Figure 1 6 PACKAGE AIR OIL FLOW DIAGRAM 202EDM797 Ref Drawing ...

Страница 14: ... lifting angle must not exceed 15 degrees Failure to observe this warning may result in damage to equipment or personal injury Compressor air oil reservoir separator chamber and all piping and tubing may be at high temperature during and after operation LOCATION The compressor should be installed whenever possible in a clean well lighted well ventilated area with ample space all around for mainten...

Страница 15: ... the air flow to and from the unit Allow three and one half 3 1 2 feet 1 1 m to the nearest obstruction on the starter end and control box end of the unit Allow three 3 feet 9 m to the nearest obstruction above and on other sides of unit For continuous efficiency oil cooler cores must be periodically cleaned with either vacuum or compressed air If wet cleaning is required shield motor and spray on...

Страница 16: ...fficient to conveniently drain the oil some other methods of providing drain are 1 Elevate the compressor unit on a suitable structure to obtain the desired drain height If the compressor unit base is raised above floor level the space between the floor 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...

Страница 17: ...utside installations Cold Weather Down To 10 F 12 C 1 Be sure all drains traps and control lines including pressure transducer lines are heated to avoid freezing of condensate Heat tape with thermostat control is generally satisfactory for this purpose and can be obtained at various local plumbing or hardware outlets at nominal cost 2 If an air cooled aftercooler is to be used provisions to bypass...

Страница 18: ... in the operation and installation of the unit Refer to Engineering Data Sheet 13 9 411 available from an authorized Gardner Denver distributor for the advantages of using the heat recovered from rotary compressors This heat recovery could easily pay for an adequate shelter for the unit AUXILIARY AIR RECEIVER An auxiliary air receiver is not required if the piping system is large and provides suff...

Страница 19: ...and corner of the unit viewed from the opposite end from control panel side When connecting two or more GD rotary screw units on a common manifold each unit is isolated by the check valve in the unit discharge line If a Gardner Denver rotary screw unit is connected to another compressor on a common manifold be sure the other compressor has a check valve in the line between the machine and the mani...

Страница 20: ...Maximum Water Flow gpm Approximate Water Pressure Drop 90 F Water Temperature psi 200 EAU99P 3 0 3 7 5 0 7 5 110 250 EAU99P 3 8 4 8 6 4 9 5 110 300 EAU99P 4 6 5 8 7 7 11 6 110 Less than 1 psi for any flow rate shown in the table Flows exceeding Maximum Water Flow will cause severe erosion and will void unit warranty AFTERCOOLER INTERNATIONAL Water Temperature to Heat Exchanger ls kw Model 16 C 21 ...

Страница 21: ...other water system equipment The heat exchanger system is designed to operate with water inlet temperatures from 60 F to 90 F 16 C to 32 C and a water outlet temperature not to exceed 110 F 43 C If water cooler than 60 F is used high water outlet temperatures over 110 F 43 C will be experienced along with shortened heat exchanger life caused by tube fouling and corrosion If water warmer than 90 F ...

Страница 22: ...13 10 615 Page 21 Figure 2 8 PARALLEL PIPING OPTIONAL WATER CONTROL VALVE AND WATER SHUTOFF VALVE MUST BE ORDERED SEPARATELY 306EAQ797 A Ref Drawing ...

Страница 23: ...ted since 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 suitable for the environment with two 2 rejection type control circuit fuses size according to motor starter manufacturer s standard a 200 208 volt coil and three 3 overload heaters for 200 208 vol...

Страница 24: ...ng 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 MANUFACTURER TRADE NAME CHEVRON SRI 2 SHELL DOLIUM R EXXON UNIREX 2 EXXON POLYREX ELECTRIC MOTOR REGREASING INTERVAL Type of Service Typical Rating Relubrication Interval Up to 150 HP 112 kW 18 Months Standard...

Страница 25: ...ssary to achieve maximum service and extended drain intervals of AEON 9000SP synthetic lubricant Use only genuine Gardner Denver filters designed and specified for this compressor Before removing the oil filler plug always stop the unit and release air pressure lockout and tagout the power supply to the starter Failure to release pressure or properly disconnect the power may result in personal inj...

Страница 26: ...an one revolution if possible Never allow motor to reach full speed 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 NOT EXCEED THE MAXIMUM OPERATING PRESSURE ON THE COMPRESSOR NAMEPLATE See Controller Manual 13 9 653 for procedure Operation at excessive discha...

Страница 27: ... the 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 required If the unit is a water cooled heat exchanger model open any manual water inlet valves wide open Start the unit by pushing either the CONSTANT RUN button or one of the AUTO buttons DAILY CHECK...

Страница 28: ...message window Press the STOP RESET key at any time to stop the compressor under normal conditions Detailed instructions for the controller are found in the manual 13 9 653 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 CONTROL DEVICES Controller This compressor unit featur...

Страница 29: ... clear of the discharge port when testing the relief valve to prevent injury Never paint lubricate or alter a relief valve Do not plug vent or restrict discharge Operation 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 1 SCHEMATIC TUBING DIAGRAM 205EAU797 A Ref Drawing C C CA A A...

Страница 30: ...r even if the air service valve is fully open to atmospheric pressure This valve also functions as a check valve to prevent back flow of air from the shop air line when the unit stops unloads or is shut down The valve incorporates a spring loaded piston which maintains approximately 65 psig in the oil reservoir When the air pressure on the upstream reservoir side of the valve rises above 65 psig t...

Страница 31: ...h valves de energized the normally open IVC valve allows control pressure to the inlet piston to close the valve If IVC only is energized the inlet valve is held in its current position If both valves are energized control pressure is relieved from the inlet piston to allow the valve to open Pressure Regulator The pressure regulator is used to supply a constant and low control pressure to prevent ...

Страница 32: ...Valve Actuator Figure 4 6 page 31 The turn valve actuator is a rotary rack and pinion device which positions the turn valve according to system demand Filtered oil from the reservoir is directed to the outboard ends of the two actuating cylinders to move the rack and rotate the valve Located on the end of the cylinders are adjusting screws which limit the travel of the actuator When looking at the...

Страница 33: ... shutdown the compressor if temperature problems occur at the separator Emergency Stop Pushbutton This is a maintained pushbutton and removes power from the controller outputs regardless of controller status It is located on the upper section of the panel next to the keypad This should be used for emergency purposes only use the keypad STOP RESET for normal controlled stopping Automatic restarting...

Страница 34: ...um 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 PSIG Compressor Delivery Inlet Valve Position Turn Valve Position Discharge Manifold Pressure psi Full Capacity Open Closed 100 70 Capacity Open 50 Open 100 40 Capacity Open Full Open 100 30 Capacity Closing Full Open 103 20 Capacit...

Страница 35: ...13 10 615 Page 34 Figure 4 7 CONTROL SCHEMATIC COMPRESSOR AT FULL LOAD 206EAU797 B Ref Drawing ...

Страница 36: ...13 10 615 Page 35 Figure 4 8 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH OFF 207EAU797 B Ref Drawing ...

Страница 37: ...13 10 615 Page 36 Figure 4 9 CONTROL SCHEMATIC COMPRESSOR FULLY UNLOADED LOW DEMAND MODE SWITCH ON 208EAU797 B Ref Drawing ...

Страница 38: ...13 10 615 Page 37 Figure 4 10 WIRING DIAGRAM WYE DELTA ES CONTROLLER AIR COOLED 202EAU546 D Ref Drawing ...

Страница 39: ...13 10 615 Page 38 Figure 4 11 WIRING DIAGRAM WYE DELTA ES CONTROLLER WATER COOLED 205EAU546 D Ref Drawing Page 1 of 2 ...

Страница 40: ...13 10 615 Page 39 205EAU546 D Ref Drawing Page 2 of 2 ...

Страница 41: ...s and are factory authorized tested and approved for use in rotary screw compressors AEON lubricants are available through your authorized Gardner Denver compressor distributor OIL SPECIFICATIONS EAU Domestic and International The factory fill compressor lubricant is Gardner Denver AEON 9000SP lubricating coolant which can be used for year round operation AEON 9000SP is a synthetic extended life l...

Страница 42: ...ve controls the 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 valve may result in moisture accumulation which is detrimental to compressor lubrication and may cause excessive oil carryover in the lubricant or compressor failure Please note that the...

Страница 43: ...EW POINT CHART F Figure 5 2 DEW POINT CHART C These charts are easily used by reading the ambient temperature 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 Dew Point Temperature vs Ambient Temperature 100 Relative Humidity 20 30 40 50 60 70 80 90 100 110 10 5 0 5 10 15 20 25 30 3...

Страница 44: ...13 10 615 Page 43 Figure 5 3 FLOW DIAGRAM 210EAU797 B Ref Drawing ...

Страница 45: ...13 10 615 Page 44 Figure 5 4 OIL FLOW DIAGRAM REMOTE OVERHEAD MOUNTED 205EDM797 Ref Drawing 202EAU797 Ref Drawing ...

Страница 46: ...nts of local codes should be followed When connecting pipe fittings to the cooler support the threaded coupling with a pipe wrench when tightening the connection Use silicone sealant on all steel to aluminum threaded connections All piping should be firmly supported to avoid strain on the cooler manifold and connections Flexible connections should be installed in all interconnecting piping adjacen...

Страница 47: ... the minimum pressure check valve then into piping to the cooler with a flexible connection between the minimum pressure check valve and aftercooler to keep the weight of the piping off of the cooler HEAT EXCHANGER OIL PIPING All remote elevated cooler applications must be sent through Engineering for approval and for recommending pipe size When the cooling module is removed from the package the t...

Страница 48: ...stallations with pipe lengths and or vertical runs outside the recommended limits could result in high oil carryover and cause the machine to shutdown on high discharge temperature COLD AMBIENT OPERATION See Installation for Cold Weather Operation page 16 ADDITION OF OIL BETWEEN CHANGES must be made when the oil level is in the red range on the gauge as read while the unit is on To add oil follow ...

Страница 49: ... used filter 2 Fill the system with a 50 percent charge of the new lubricant Start the machine and stay there to observe Allow the machine to run about five minutes at temperature or until temperature stabilizes then shut down 3 Thoroughly drain the machine 4 Change to a new filter and separator 5 Fill the system with a full charge of the new lubricant then reinstall drain plug 6 Machine should th...

Страница 50: ...d on oil temperature Figure 5 7 shows how the change interval is affected by temperature When operating conditions are severe very dusty high humidity etc it will be necessary to change the oil more frequently Operating conditions and the appearance of the drained oil must be surveyed and the oil change intervals planned accordingly by the user Gardner Denver offers a free oil analysis program wit...

Страница 51: ...the following methods 1 If the unit is not elevated high enough to use the oil reservoir drain line to drain oil a small hand electric or air operated pump should be used to drain reservoir through the oil filler opening or from the drain valve 2 If the unit is elevated so that the oil reservoir drain can be used empty the oil reservoir through the drain valve to a suitable container or sump 3 If ...

Страница 52: ...el 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 DO NOT DRAIN OIL TO CORRECT On the next start oil will again fill the system and the gauge will indicate operating at the proper level DO NOT OVERFILL as oil carryover will result The quantity of oil required to raise the o...

Страница 53: ...s Compressor air oil reservoir separation chamber and all piping and tubing may be at high temperature during and after operation Improper oil filter maintenance will cause damage to equipment Replace filter element every 1000 hours of operation More frequent replacement could be required depending on operating conditions A filter element left in service too long may damage equipment Use the follo...

Страница 54: ...tabs on the filter element with the channels in the filter head and snap the element into the filter head 7 Press the filter assembly into the filterstat assembly Using a 1 socket tighten down the oil filter until the o ring seals Do not overtighten 8 Run the unit and check for leaks COMPRESSOR OIL COOLER RADIATOR TYPE Figure 1 5 page 11 and Figure 1 6 page 12 The oil cooler motor and fan is mount...

Страница 55: ...eath Shut down compressor relieve system of all pressure disconnect lockout 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 temperature during and after operation It is mandatory that any water cooled unit be installed in a shelter heated to temperatures abov...

Страница 56: ...periodically and replaced when the zinc has been reduced to about 1 2 inch 13mm in length Figure 5 10 WATER CONTROL VALVE WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER Optional Equipment Figure 5 10 The water flow control valve is adjustable to compensate for varying water inlet temperatures and pressures and is to be mounted in the water outlet line after the oil cooler Figure 5 3 page 43 Use the c...

Страница 57: ...d in the water outlet line after the oil cooler The valve should be wired into the compressor control circuit so that the valve opens to allow water to flow any time the compressor is running When compressor stops under automatic control or is shut off manually the valve should close stopping water flow through the system See Wiring Diagrams pages 32 thru 35 Compressor air oil reservoir separation...

Страница 58: ... of the unit will also hamper separation and cause oil carryover Oil separator element life cannot be predicted it will vary greatly depending on the conditions of operation the quality of the oil used and the maintenance of the oil and air filters The condition of the separator can be determined by pressure differential gauging or by inspection Pressure Differential Gauging The CHANGE SEPARATOR a...

Страница 59: ...erating temperature at the time of checks One half hour of loaded operation is usually sufficient to reach level out operating temperatures Air and Oil Discharge Temperature 165 F to 195 F 74 C to 91 C Read at gauge on the instrument panel or check with a thermometer at the discharge housing Compressor Oil Inlet Temperature 150 F to 160 F 66 C to 71 C Install a tee at the oil filter outlet and che...

Страница 60: ... same as the air discharge temperature see the gauge on the instrument panel The oil outlet temperature may be checked by installing a tee at the oil filter outlet Oil Cooler Water Pressure Differential Water Cooled Heat Exchanger The water pressure differential through the heat exchanger will depend on the supply pressure flow rate cooler tube cleanliness and outlet pressure The inlet and outlet ...

Страница 61: ...uine parts are available through your authorized Gardner Denver distributor To service 1 Unfasten the clips and pull out the filter element 2 Visually inspect the element If cleaning is not necessary reinstall the filter element If the element requires cleaning follow steps 3 4 and 5 3 Wash the element by soaking about 15 minutes in warm water with a mild non sudsing detergent Rinse the element th...

Страница 62: ...es a 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 below three 3 inches 76 mm of water with the compressor running at full load would indicate a rupture or crack Inlet Tube Inspect the inlet screen and tube for dirt accumulation each time the filter is serviced Cl...

Страница 63: ...rn 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 with a single element cushion The coupling does not require lubrication If maintenance on mating parts is required reassemble coupling as follows ...

Страница 64: ...asher 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 element is centered using the loctite supplied with the coupling lock all set screws to 50 ft lbs If element is not centered unlock set screws and slide coupling to center element between shaft en...

Страница 65: ...ric 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 all set screws must have loctite supplied with the coupling applied 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 ...

Страница 66: ... is high refer to Excessive Oil Consumption page 68 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 accumulation on oil aftercooler core faces and the cooling fan If cleaning is required clean the exterior fin surfaces of the cores by blowing compressed ai...

Страница 67: ...roller Every 8 Hours Every 125 Hours Every 1000 Hours Every 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 Element Change Compressor Lubricant AEON 9000SP Check Relief Valve See Oil Change Interval Chart Figure 5 7 page 49 for specific lubricant lif...

Страница 68: ...h discharge 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 investigate cause of overload Compressor does not unload or load 1 Improperly adjusted control 1 Refer to Manual 13 9 653 and adjust control 2 Air leak in control lines 2 Determine source of leak and c...

Страница 69: ...aks 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 See Manual 13 9 653 Excessive oil consumption 1 Oil carryover through lines 1 See Oil Carryover in this section 2 Oil leaks at all fittings and gaskets 2 Tighten or replace fittings or gaskets 3 Shaft seal leaking 3 Replace shaft se...

Страница 70: ...000SP lubricating coolant 6 Inoperative minimum pressure valve 6 Clean out or replace valve 7 Operation at elevated discharge temperatures 7 Reduce temperature See High Discharge Air Temperature this section 8 Scavenge line check valve failure 8 Replace check valve 9 Water condensate in oil 9 Check oil reservoir temperature and if low change thermal mixing valve element to higher temperature NOTIC...

Страница 71: ...f 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 service personnel for repair or replacement of any product or part thereof which in the Company s judgment is proved not to be as warranted Labor shall be limited to the amount specified in the Company ...

Страница 72: ...Compressor Division 1800 Gardner Expressway Quincy Illinois 62305 Telephone 800 682 9868 FAX 217 224 7814 Visit our Web Site www gardnerdenver com Sales and Service in all major cities Specifications subject to change without notice Copyright 2009 Gardner Denver Inc Litho in U S A ...

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