Gardner Denver ELECTRA-SAVER Operating And Service Manual
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Gardner Denver ELECTRA-SAVER Operating And Service Manual

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13-21-601
Version: 02
March 15, 2011
ELECTRA-SAVER
ELECTRA-SAVER II
STATIONARY BASE-MOUNTED
COMPRESSOR
With
™
AirSmart
Controller
EAH99D - 50 HP
EBH99H - 40, 50 HP
EAM99D, EBM99M - 60, 75 HP
EAP99K, EBP99K - 100 HP
INTERNATIONAL MODELS
EBM99N 60, 75, 100 HP (45, 56, 75 KW)
OPERATING AND
SERVICE MANUAL
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Summary of Contents for Gardner Denver ELECTRA-SAVER

  • Page 1 13-21-601 Version: 02 March 15, 2011 ELECTRA-SAVER ELECTRA-SAVER II STATIONARY BASE-MOUNTED COMPRESSOR With ™ AirSmart Controller EAH99D - 50 HP EBH99H - 40, 50 HP EAM99D, EBM99M - 60, 75 HP EAP99K, EBP99K - 100 HP INTERNATIONAL MODELS EBM99N 60, 75, 100 HP (45, 56, 75 KW)

  • Page 2: Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services

    Remanufacturing Center in Indianapolis, IN., for purchase on an exchange basis with liberal core credit available for the replacement unit. 3. A full line of factory tested AEON™ compressor lubricants specifically formulated for use in Gardner Denver compressors.

  • Page 3: Warning - Prohibition - Mandatory Label Information

    WARNING – PROHIBITION – MANDATORY LABEL INFORMATION Gardner Denver Rotary Screw compressors are the result of advanced engineering and skilled manufacturing. To be assured of receiving maximum service from this machine, the owner must exercise care in its operation and maintenance. This book is written to give the operator and maintenance department essential information for day-to-day operation, maintenance and adjustment.
  • Page 4 Indicates a hazard with a medium level of risk which, if not avoided, COULD result in death or serious injury. Asphyxiation Hazard – Poisonous Fumes or Toxic Gases in Compressed Air Indicates a hazard with a low level of risk which, if not avoided, MAY result in a minor or moderate injury.

  • Page 5: Safety Precautions

    SAFETY PRECAUTIONS Safety is everybody’s business and is based on your use of good common sense. All situations or circumstances cannot always be predicted and covered by established rules. Therefore, use your past experience, watch out for safety hazards and be cautious. Some general safety precautions are given below: Failure to observe these notices could result in injury to or death of personnel.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS Maintain Compressor Reliability And Performance With Genuine Gardner Denver Compressor Parts And Support Services ................1 Instructions For Ordering Repair Parts/Remanufactured Airends ..............1 Warning – Prohibition – Mandatory Label Information.................. 2 Safety Precautions ............................4 Index................................6 List Of Illustrations............................

  • Page 7: Index

    INDEX Addition Of Oil Between Changes ....80 Inlet Valve ............32 Aftercooler Piping..........78 Installation For Cold Weather Operation ..16 Installation, Section 2........13 Air Filter Element Life........93 Air Filter Vacuum Switch ........34 Lifting Unit ............13 Air Filter, Heavy Duty (Standard) .....92 Air Filter, Section 6...........92 Location ............
  • Page 8 Parallel Piping ..........21 Service Check List Piping Air Filter ............97 Series............20 Shuttle Valve............ 33 Power Supply ...........35 Solenoid Valves Ivc And Ivo ......33 Pressure Differential Gauging ......89 Solenoid Valves Tvc And Tvo......34 Pressure Regulator ..........33 Starting & Operating Procedures, Section 3..23 Prestart-Up Instructions ........23 Starting The Unit ..........

  • Page 9: List Of Illustrations

    Figure 4-5 – Inlet Valve ..............................32 Figure 4-6 – Shuttle Valve............................33 Figure 4-7 – Turn Valve – Electra-Saver Only ......................34 Figure 4-8 – Control Schematic – Compressor Unloaded – Constant Speed Mode ............37 Figure 4-9 – Control Schematic – Compressor At Full Load – Constant Speed Mode..........38 Figure 4-10 –...

  • Page 10: Section 1, General Information

    GENERAL INFORMATION Figure 1-1 – COMPRESSION CYCLE COMPRESSOR - The Gardner Denver Rotary Screw compressor is a single stage, positive displacement rotary machine using meshing helical rotors to effect compression. Both rotors are supported between high capacity roller bearings located outside the compression chamber. Single width cylindrical roller bearings are used at the inlet end of the rotors to carry part of the radial loads.

  • Page 11: Cooling, Sealing And Lubrication

    TURN VALVE (ELECTRA-SAVER ONLY) - 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.

  • Page 12: Figure 1-4 - Compressor / Motor Side

    Figure 1-4 – COMPRESSOR / MOTOR SIDE 217ECM797-A (Ref. Drawing) Figure 1-5 – COOLER / RESERVOIR SIDE 13-21-601 Page 11...

  • Page 13: Figure 1-6 - Air/Oil Flow Diagram

    219ECM797-A (Ref. Drawing) Figure 1-6 – AIR/OIL FLOW DIAGRAM 13-21-601 Page 12...

  • Page 14: Section 2, Installation

    SECTION 2 INSTALLATION GENERAL - On receipt of the unit, check for any damage that may have been incurred during transit. Report any damage or missing parts as soon as possible Do not electric weld on the compressor or base; bearings can be damaged by passage of current.

  • Page 15: Air-Cooled Units, Location

    Both the air-cooled and water-cooled units require cooling air as well as air to the compressor inlet. Proper ventilation MUST be provided; hot air must be exhausted from the compressor operating area. A typical inlet-outlet air flow arrangement is shown in Figure 2-1. Figure 2-1 –...

  • Page 16: Oil Reservoir

    (.9 m) to the nearest obstruction above and on other sides of the unit. FOUNDATION - The Gardner Denver Rotary Screw compressor requires no special foundation, but should be mounted on a smooth, solid surface. Whenever possible install the unit near level. Temporary installation may be made at a maximum 10°...

  • Page 17: Cold Weather Operation

    Provide at least some simple shelter such as a plywood windbreak to protect against drifting snow. Use only Gardner Denver AEON 9000 SP lubricant. Monitor the unit carefully during start-up and operation to be sure it is functioning normally.

  • Page 18: Auxiliary Air Receiver

    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.

  • Page 19: Blowdown Valve Piping

    DISCHARGE SERVICE LINE - The discharge service line connection on both water-cooled and air- cooled units is made at the right hand corner of the unit, viewed from the opposite end from control panel side. When manifolding two or more rotary screw units on the same line, each unit is isolated by the check valve in the unit discharge line.

  • Page 20: Figure 2-6 - Aftercooler Approximate Water Flow

    AFTERCOOLER Water Temperature to Heat Exchanger Gallons/minute Maximum Water Approximate Water Flow Pressure Drop @ 90° F Model 60° F 70° F 80° F 90° F Gallons/minute * Water Temperature PSI EBH99H 26.0 EAH99D 26.0 EBH99H EAM99D Less than 1 PSI for any 26.0 EBM99M flow rate shown in the table...

  • Page 21: Figure 2-7 - Series Piping

    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°...

  • Page 22: Electrical Wiring

    PARALLEL PIPING (Figure 2-8, page 20) - A separate water control valve is required to control the discharge air temperature. If a remote (externally mounted) water-cooled aftercooler is piped in parallel with the heat exchanger, provide a separate water control valve for the aftercooler and pipe separate inlet water lines to both the aftercooler and heat exchanger.

  • Page 23: Lubrication Motor

    MOTOR LUBRICATION - Long time satisfactory operation of an electric motor depends in large measure on proper lubrication of the bearings. The following charts show recommended grease qualities and regreasing intervals for ball bearing motors. For additional information refer to the motor manufacturer’s instructions.

  • Page 24: Section 3, Starting & Operating Procedures

    Compressor Oil - Check the oil level in the reservoir. Add oil only if the oil level gauge reads in the red “ADD OIL” range. Do not mix different type oils. The unit is shipped filled with Gardner Denver AEON 9000 SP Lubricating Coolant which is suitable for the first 8000 hours under normal operating conditions.
  • Page 25 Electrical - Check the wiring diagrams furnished with the unit to be sure it is properly wired. See Figure 4-14 Page 43 thru , page 56, for general wiring diagrams and Section 2, for Figure 4-20 installation instructions. Grounding - Equipment must be properly grounded according to Section 250 of the National Electrical Code.

  • Page 26: Check Daily

    The compressor starts and stops automatically. Automatic restarting can cause injury or death. Open, lockout and tagout main disconnect and any other circuits before servicing the unit. STARTING THE UNIT - Observe the following starting procedures. Unit Cold - If the unit is a water-cooled heat exchanger model, open any manual water inlet valves wide open.

  • Page 27: Quick Start Guide

    Quick Start Guide Operation of the AirSmart controller is easy. Simply select a Target Pressure and then press the Run button to start the compressor, no other settings are required. The Target Pressure comes preset to 100 PSI from the factory. The Unload Pressure is preset to 110 PSI. If a different pressure setting is desired, the following steps can be used as a guide.
  • Page 28 To change the Target Pressure, press the Enter button to edit the value. OPERATION ADJUSTMENT TARGET PRESSURE 100 PSI (EDIT PARAMETER) A flashing cursor will appear covering the least significant digit in the Target Pressure value, use the Plus and Minus buttons to change its value.

  • Page 29: Section 4, Controls & Instrumentation

    SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION - The Gardner Denver Rotary Screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at the time of ordering. It is necessary only to connect the compressor unit to the correct power supply and to the shop air line (and to the appropriate water supply if water-cooled).

  • Page 30: Figure 4-1 - Key Pad

    Figure 4-1 – KEY PAD Relief Valve - A pressure relief valve(s) is (are) installed in the final discharge line and set to approximately 120-125% of the unit’s full load operating pressure for protection against over pressure. Periodic checks should be made to ensure its (their) operation. The relief valve should be tested for proper operation at least once every year.

  • Page 31: Figure 4-2 - Schematic Tubing Diagram

    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. 211ECM797-B (Ref. Drawing) Figure 4-2 – SCHEMATIC TUBING DIAGRAM 13-21-601 Page 30...

  • Page 32: Blowdown Valve

    Figure 4-3 – BLOWDOWN VALVE Blowdown Valve (Figure 4-3) - This valve normally is used for control functions, but also serves to relieve reservoir pressure following a shutdown. The blowdown valve is a two-way solenoid valve which is piped into the oil reservoir outlet ahead of the minimum pressure valve. When the solenoid is de- energized, the valve opens and the coolant system is blown down.

  • Page 33: Inlet 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. The internal parts will come out after the cap has been removed. Repair kits are available from your local authorized Gardner Denver distributor. 224ECM797-B (Ref.

  • Page 34: Figure 4-6 - Shuttle Valve

    Solenoid Valves IVC and IVO - These valves control position of the inlet valve in response to signals from the “AirSmart” Controller. With both 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.

  • Page 35: Air Filter Vacuum Switch

    Figure 4-7 – TURN VALVE – ELECTRA-SAVER ONLY Turn Valve (Electra-Saver only) (Figure 4-7)- The turn valve is a helical valve which, when rotated, opens and closes a series of ports cast into the compressor cylinder. When these ports are open, they direct some of the air which would otherwise be compressed back to the inlet, reducing both capacity and power consumption.

  • Page 36: Discharge Thermistor

    Discharge Thermistor - This sensor is located directly in the compressor discharge. Its signal is used to monitor compressor temperature and shut down the compressor if a coolant problem is detected. Reservoir Thermistor - This sensor is located near the separator and is used to monitor temperature and shut down the compressor if high temperatures are detected.

  • Page 37: Compressor Capacity Control - Turn Valve Units Only

    COMPRESSOR CAPACITY CONTROL - TURN VALVE UNITS ONLY The capacity of the compressor is controlled by the action of the turn valve and the compressor inlet valve. The turn valve controls compressor delivery to match demands of 40% to 100% of the compressor’s maximum capacity.

  • Page 38: Figure 4-8 - Control Schematic - Compressor Unloaded - Constant Speed Mode

    225ECM797-B (Ref. Drawing) Figure 4-8 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – CONSTANT SPEED MODE EBH, EBM, EBP UNITS ONLY...

  • Page 39: Figure 4-9 - Control Schematic - Compressor At Full Load - Constant Speed Mode

    226ECM797-B (Ref. Drawing) Figure 4-9 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD – CONSTANT SPEED MODE EBH, EBM, EBP UNITS ONLY...

  • Page 40: Figure 4-10 - Control Schematic - Compressor Unloaded - Low Demand Mode Or Auto Mode

    227ECM797-B (Ref. Drawing) Figure 4-10 – CONTROL SCHEMATIC – COMPRESSOR UNLOADED – LOW DEMAND MODE OR AUTO MODE EBH, EBM, EBP UNITS ONLY...

  • Page 41: Figure 4-11 - Control Schematic - Compressor At Full Load

    214ECM797-B (Ref. Drawing) Figure 4-11 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD EAH, EAM, EAP UNITS ONLY...

  • Page 42: Figure 4-12 - Control Schematic - Compressor Fully Unloaded - Low Demand Mode Switch Off

    215ECM797-B (Ref. Drawing) Figure 4-12 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE SWITCH OFF EAH, EAM, EAP UNITS ONLY...

  • Page 43: Figure 4-13 - Control Schematic - Compressor Fully Loaded - Low Demand Mode Switch On

    216ECM797-B (Ref. Drawing Figure 4-13 – CONTROL SCHEMATIC – COMPRESSOR FULLY LOADED – LOW DEMAND MODE SWITCH ON EAH, EAM, EAP UNITS ONLY...

  • Page 44: Figure 4-14 - Wiring Diagram - Wye Delta (Air-Cooled / Water-Cooled) - 200, 230, 460 Volt

    328EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-14 – WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) - 200, 230, 460 VOLT...
  • Page 45 328EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) - 200, 230, 460 VOLT...

  • Page 46: Figure 4-15 - Wiring Diagram - Wye Delta (Air-Cooled / Water-Cooled) - 575 Volt

    331EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-15 – WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) - 575 VOLT...
  • Page 47 331EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) - 575 VOLT...

  • Page 48: Figure 4-16 - Wiring Diagram - Full Volt (Air-Cooled / Water-Cooled) - 200 & 230 Volt

    329EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-16 – WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 200 & 230 VOLT...
  • Page 49 329EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 200 & 230 VOLT...

  • Page 50: Figure 4-17 - Wiring Diagram - Full Volt (Air-Cooled / Water-Cooled) - 460 Volt

    334EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-17 – WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 460 VOLT...
  • Page 51 334EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 460 VOLT...

  • Page 52: Figure 4-18 - Wiring Diagram - Full Volt (Air-Cooled / Water-Cooled) - 575 Volt

    332EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-18 – WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 575 VOLT...
  • Page 53 332EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 575 VOLT...

  • Page 54: Figure 4-19 - Wiring Diagram - Less Starter (Air-Cooled / Water-Cooled) - 200, 230, 460 Volt

    330EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-19 – WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 460 VOLT...
  • Page 55 330EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 460 VOLT...

  • Page 56: Figure 4-20 - Wiring Diagram - Less Starter (Air-Cooled / Water-Cooled) - 575 Volt

    333EAH546-C (Ref. Drawing) Page 1 of 2 Figure 4-20 – WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT...
  • Page 57 333EAH546-C (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT...

  • Page 58: Figure 4-21 - Wiring Diagram - Wye Delta (Air-Cooled / Water-Cooled) - 200/230 Volt

    311EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-21 – WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) – 200/230 VOLT...
  • Page 59 311EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) – 200/230 VOLT...

  • Page 60: Figure 4-22 - Wiring Diagram - Wye Delta (Air-Cooled / Water-Cooled) - 380/460 Volt

    310EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-22 – WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) – 380/460 VOLT...
  • Page 61 310EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) – 380/460 VOLT...

  • Page 62: Figure 4-23 - Wiring Diagram - Wye Delta (Air-Cooled / Water-Cooled) - 575 Volt

    312EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-23 – WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) – 575 VOLT...
  • Page 63 312EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – WYE DELTA (AIR–COOLED / WATER–COOLED) – 575 VOLT...

  • Page 64: Figure 4-24 - Wiring Diagram - Full Volt (Air-Cooled / Water-Cooled) - 200 & 230 Volt

    314EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-24 – WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 200 & 230 VOLT...
  • Page 65 314EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 200 & 230 VOLT...

  • Page 66: Figure 4-25 - Wiring Diagram - Full Volt (Air-Cooled / Water-Cooled) - 380/460 Volt

    313EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-25 – WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 380/460 VOLT...
  • Page 67 313EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 380/460 VOLT...

  • Page 68: Figure 4-26 - Wiring Diagram - Full Volt (Air-Cooled / Water-Cooled) - 575 Volt

    315EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-26 – WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 575 VOLT...
  • Page 69 315EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – FULL VOLT (AIR–COOLED / WATER–COOLED) – 575 VO...

  • Page 70: Figure 4-27 - Wiring Diagram - Less Starter (Air-Cooled / Water-Cooled) - 200, 230, 380, 460 Volt

    316EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-27 – WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 380, 460 VOLT...
  • Page 71 316EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 200, 230, 380, 460 VOLT...

  • Page 72: Figure 4-28 - Wiring Diagram - Less Starter (Air-Cooled / Water-Cooled) - 575 Volt

    317EAM546-A (Ref. Drawing) Page 1 of 2 FIGURE 4-28 – WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT...
  • Page 73 317EAM546-A (Ref. Drawing) Page 2 of 2 WIRING DIAGRAM – LESS STARTER (AIR–COOLED / WATER–COOLED) – 575 VOLT...

  • Page 74: Section 5, Lubrication, Oil Cooler, Oil Filter & Separator

    AEON lubricants are available through your authorized Gardner Denver compressor distributor. OIL SPECIFICATIONS - The factory fill compressor lubricant is Gardner Denver AEON 9000 SP lubricating coolant which can be used for year-round operation. AEON 9000 SP is a synthetic, extended life lubricant which can extend lubricant change intervals up to 4 times that of a petroleum based lubricant.

  • Page 75: High Temperature Operation

    HIGH TEMPERATURE OPERATION - Gardner Denver AEON 9000 SP lubricating coolant will operate at a sustained discharge temperature up to 210° F (99° C). When unusually high ambient air temperature is encountered, it will shorten the lubricant life; see Figure 5-7, page 82.

  • Page 76: Figure 5-1 - Dew Point Chart °F

    Dew-Point Temperature vs. Ambient Temperature (100% Relative Humidity) 100 psig 125 psig 150 psig 175 psig Ambient Temp. F Figure 5-1 – DEW POINT CHART °F Dew -Point Tem perature vs. Am bient Tem perature (100% Relative Hum idity) 6.9 bar 8.6 bar 10.4 bar 12.1 bar...

  • Page 77: Figure 5-3 - Flow Diagram - Air/Oil System

    221ECM797-B (Ref. Drawing) Figure 5-3 – FLOW DIAGRAM – AIR/OIL SYSTEM...

  • Page 78: Figure 5-4 - Oil Flow Diagram - Remote Overhead Mounted Cooler

    201EAP797-A (Ref. Drawing) 218ECM797-A (Ref. Drawing) Figure 5-4 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED COOLER 13-21-601 Page 77...

  • Page 79: Aftercooler Piping

    REMOTE MOUNTED ELEVATED COOLER ASSEMBLY PROCEDURE - The Compressor package will be built and tested with the coolers mounted on the package. On enclosed units, the fan motor will be disconnected after test and the vent fan motor connected in its place. The vent fan will be mounted in the enclosure.

  • Page 80: Heat Exchanger (Oil) Piping

    NOTICE When removing the cooling module from the package for remote operation, do not use the flexible coupling (when supplied) between the air/oil separator housing and the minimum pressure/check valve. The discharge piping from the air/oil separator housing should be piped into 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.

  • Page 81: Addition Of Oil Between Changes

    Failure to install these parts or installations with pipe lengths and/or vertical runs outside the recommended limits, could result in high oil carryover and cause the machine to shut down on high discharge temperature. COLD AMBIENT OPERATION - See “Installation for Cold Weather Operation,” Section 2. 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.

  • Page 82: Oil Change Interval

    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 with the AEON lubricants and we recommend a sample be sent in at 100 hours on a new unit.

  • Page 83: Draining And Cleaning Oil System

    Discharge AEON 4000 AEON 9000 SP Temperature Change Interval Change Interval 4000 hrs. 8000 hrs. Up to 180° F (82° C) 3000 hrs. 6000 hrs. 180° F to 190° F (82° C to 88° C) 2000 hrs. 4000 hrs. 190° F to 200° F (88° C to 93° C) 1000 hrs.

  • Page 84: Filling Oil Reservoir

    FILLING OIL RESERVOIR Air/oil under pressure will cause severe personal injury or death. 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. Be sure the unit is completely off and that no air pressure is in the oil reservoir. Disconnect, lockout and tagout the power supply to the starter.

  • Page 85: Oil Filter

    COMPRESSOR OIL FILTER (Figure 5-3, Page 76) - This screw on oil filter is a vital part in maintaining a trouble-free compressor, since it removes dirt and abrasives from the circulated oil. The oil filter relief valve is located in the oil filter head. The relief valve opens in the event the element becomes dirty enough to block the flow of oil.

  • Page 86: Compressor Oil Cooler - Water-Cooled Heat Exchanger

    COMPRESSOR OIL COOLER - RADIATOR TYPE (Figure 1-5, page 11) - The oil cooler motor and fan is mounted on the oil cooler module; air is exhausted through the oil cooler and away from the unit. Do not obstruct air flow to and from the oil cooler. Allow a minimum of three (3) feet clearance around the cooler. Keep both faces of cooler core clean for efficient cooling of compressor oil.

  • Page 87: Figure 5-10 - Water Control Valve

    It is mandatory that any water-cooled unit be installed in a shelter heated to temperatures above freezing (32° F, 0° C). Oil cooler malfunction may be traced by checking pressure at oil inlet and outlet. At normal operating air service pressure (65 psig to 150 psig, 4.5 bar to 10.3 bar) with the unit warm, a pressure drop of 3 psi to 15 psi (.2 bar to 1 bar) can be expected between the oil inlet and the oil outlet.

  • Page 88: Figure 5-11 - Dew Point Temperature Vs. Ambient Temperature

    WATER FLOW CONTROL VALVE FOR HEAT EXCHANGER (Optional Equipment) (Figure 5-10, page 86) - 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 76). Use the compressor discharge air temperature gauge on the instrument panel in setting the flow control valve.

  • Page 89: Oil Reservoir

    WATER SHUTOFF VALVE - WATER-COOLED HEAT EXCHANGER (Optional Equipment) (Figure 5-3, page 76) - A magnetic solenoid-operated water shutoff valve rated at 150 psig (10.3 bar) water pressure should be mounted 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.

  • Page 90: Inspection

    Oil carryover malfunctions of the oil separator are usually due to using elements too long, heavy dirt or varnish deposits caused by inadequate air filter service, use of improper oil or using oil too long for existing conditions. A ruptured or collapsed separator element is usually due to heavy dirt or varnish buildup in the filtering material.

  • Page 91: Removal For Inspection Or Replacement

    Removal Of Oil Separator For Inspection Or Replacement: Air/oil under pressure will cause severe personal injury or death. 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.

  • Page 92: Oil Cooler Oil Pressure Differential (Air-Cooled Radiator)

    Oil Cooler Oil Pressure Differential (Air-Cooled Radiator) - Check differential across oil system by measuring oil inlet pressure as described above. Oil Cooler Oil Pressure Differential (Water-Cooled Heat Exchanger) – 2 psid to 25 psid (.1 bar to 1.7 bar) (65 psig to 150 psig, 4.5 bar to 10.3 bar receiver pressure) - Check that oil inlet pressure is correct or measure the differential between drains on the oil cooler shell.

  • Page 93: Section 6, Air Filter

    IMPORTANT. An improperly maintained air filter can cause a loss of compressor air delivery. Filter Element - Clean every 50 to 150 operating hours depending on dust conditions. NOTICE Use only genuine Gardner Denver air filter elements on Gardner Denver compressor units. Genuine parts are available through your authorized Gardner Denver distributor.

  • Page 94: Air Filter Element Life

    Do not oil this element. Do not wash in inflammable cleaning fluids. Do not use solvents other than water. Improper cleaning may damage the element. NOTICE Never operate the unit without the element. Never use elements that are damaged, ruptured or wet. Never use gaskets that won't seal. Keep spare elements and gaskets on hand to reduce downtime.

  • Page 95: Section 7, Coupling

    SECTION 7 COUPLING Figure 7-1 – INSTALLATION OF COUPLING CUSHIONS Rotating machinery can cause personal injury or death. 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 with a single cushion.
  • Page 96 ASSEMBLY OF COUPLING ONTO THE AIREND AND MOTOR (Figure 7-1). NOTICE Elements with non-uniform cross sections must be mounted with the rotation arrow on the coupling the same direction as the rotation arrow on the airend. Incorrect rotation will greatly decrease the torque carrying capacity of the coupling.
  • Page 97 3. Apply a light oil or grease film to both sides of the hardened steel washer. This is very important, since it will significantly reduce the rubber stresses around the metal bushings when torquing down the cap screws. Place the supplied hardened washers under the cap screw heads and torque the screws down to the torque rating in the assembly instructions supplied with the coupling.

  • Page 98: Section 8, Maintenance Schedule

    SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST Air Filter - Operating conditions determine frequency of service. See “Air Filter", Section 6. Oil Separator - Operating conditions determine frequency of service. See “Compressor Oil Separator” in Section 5, for further details. Motor Lubrication - Refer to Section 2, and Maintenance Schedule Chart, page 79.
  • Page 99 MAINTENANCE SCHEDULE Maintenance Action As Indicated Every Every Every Every by AirSmart Every 8 1000 8000 * Year Controller Hours Hours Hours Hours • Change Air Filter ............• Change Oil Separator ..........• Check Reservoir Oil Level ........• Check for Proper Load/Unload.........

  • Page 100: Section 9, Troubleshooting

    SECTION 9 TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start Wrong lead connections. Change leads. Blown fuses in control Replace fuse. box. Motor starter overload Reset and investigate tripped. cause of overload. Pressure in reservoir. Inspect blowdown valve. Read error message on Take appropriate action.
  • Page 101 SYMPTOM POSSIBLE CAUSE REMEDY Compressor starts too Wye Delta switch time set Contact your distributor. slowly too long. Minimum Pressure/Check Repair or replace. Valve is faulty. Supply voltage is too low. Check the supply voltage. Compressor is low on Restricted air filter. Clean or replace filter.
  • Page 102 NOTICE Gardner Denver factory remanufactured replacement compressor airend units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13-21-601 Page 101...
  • Page 105 1800 Gardner Expressway, Quincy, Illinois 62305 Telephone: (800) 682-9868 Telephone: (800) 682-9868 FAX: (217) 224-7814 FAX: (217) 224-7814 Specification subject to change without notice. Copyright © 2011 Gardner Denver, Inc. Litho in U.S.A Visit our Web Site: www.gardnerdenver.com Visit our Web Site: www.gardnerdenver.com...

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