Related Manuals for Gardner Denver ELECTRA–SAVER ETY99A
Summary of Contents for Gardner Denver ELECTRA–SAVER ETY99A
- Page 1 13–13–600 GARDNER DENVER 1st Edition January, 1998 ELECTRA–SAVER TWO–STAGE STATIONARY BASE–MOUNTED COMPRESSOR AUTO SENTRY –ES+ CONTROLS MODEL ETY99A – 350 HP – 500 HP OPERATING AND SERVICE MANUAL...
- Page 2 They are ready to respond and assist you by pro- Your authorized distributor can support your Gardner viding fast, expert maintenance and repair services. For the location of your local authorized Gardner Denver Air Compressor distributor refer to the yellow pages of your phone directory or contact: Distribution Center: Factory: Gardner Denver Machinery Inc.
- Page 3 FOREWORD 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 main- tenance. This book is written to give the operator and maintenance department essential information for day–to–day operation, maintenance and adjustment.
- Page 4 TABLE OF CONTENTS Maintain Compressor Reliability and Performance With Genuine Gardner Denver Compressor Parts and Support Services ................
- Page 5 INDEX Actuator, Turn Valve ..... . . Daily Check ......Addition of Oil Between Changes .
- Page 6 INDEX Oil Inlet Pressure ..... . . Lubricant Change Procedure ....Operation Lubrication, Cooling and Sealing .
- Page 7 INDEX Every Year ......Reservoir Pressure ..... System Pressure .
- Page 8 LIST OF ILLUSTRATIONS Figure # Description Page Figure 1–1 Compression Cycle ............Figure 1–2 Air Cooled Unit –...
- Page 9 SECTION 1 GENERAL INFORMATION FIGURE 1–1 – COMPRESSION CYCLE COMPRESSOR – The Gardner Denver Electra–Sav- duction and pressure increase continues until the air/oil compressor is a single stage, positive displace- mixture trapped in the interlobe cavity by the rotors ment rotary machine using meshing helical rotors to ef- passes the discharge port and is released to the oil res- fect compression.
- Page 10 compression chamber to remove heat of compression, inlet end. The valve opens and closes ports in the cylin- seal internal clearances and lubricate the rotors. der which communicates with the inlet passage. This varies the compressor rotor volume to match the de- mand for air, thus reducing the part–load power re- TURN VALVE –...
- Page 11 300ETY797 (Ref. Drawing) 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 13–13–600 Page 3...
- Page 12 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 13 Failure to observe these notices could result in damage to equipment. Stop the unit if any repairs or adjustments on or around the compressor are required. Disconnect the compressor unit from its power source, tag and lockout be- fore working on the unit – this machine is automatically controlled and may start at any time.
- Page 14 DECALS 206EAQ077 212EAQ077 218EAQ077 211EAQ077 207EAQ077 13–13–600 Page 6...
- Page 15 DECALS 216EAQ077 222EAQ077 217EAQ077 221EAQ077 208EAQ077 13–13–600 Page 7...
- Page 16 SECTION 2 INSTALLATION GENERAL – On receipt of the unit, check for any dam- that provides a cool, clean, dry source of air. In some age that may have been incurred during transit. Report cases it may be necessary to install the air filter at some any damage or missing parts as soon as possible.
- Page 17 PIPING SCHEMATIC OF COOLER PIPING SCHEMATIC OF COOLER WITH SCREWED CONNECTIONS. WITH FLANGED CONNECTIONS. FIGURE 2–3 – PIPING SCHEMATIC side of the unit and 3 feet on all other sides. Construct an oil sump or trough below the floor level and pump or bail the drained oil. Pump oil from the reservoir filler opening or drain VENTILATION –...
- Page 18 FIGURE 2–4 – PIPING DIAGRAM FOR AFTERCOOLER AND HEAT EXCHANGER The machine cannot be run blown Remote mounted elevated coolers down with remote overhead oil cool- have a maximum pipe length of 30 feet er. These units require special wiring (9 M) (each way) and a maximum height of 20 feet (6 M) with a minimum diagram –...
- Page 19 Elevation of the oil cooler above the compressor unit. Pipe type and size(s) to be used to connect the oil cooler and the compressor unit. Minimum pipe size is 2–1/2” NPT. Horizontal and vertical lengths of the pipe run. If more than one pipe size is used, list length of each size and total length.
- Page 20 The moisture separator is furnished by is used, list length of each size and total length. Gardner Denver but must be mounted by the customer Number and size of elbows, tees, unions, reduc- between the aftercooler and the auxiliary air receiver ers, and valves to be used in the pipe run.
- Page 21 Provide at least some simple shelter such as a ply- MOISTURE SEPARATOR/TRAP – Since the unit is wood windbreak to protect against drifting snow. equipped with a built–in aftercooler, a combination Use only Gardner Denver AEON 9000 SP lu- moisture separator and trap is furnished with the unit. bricant.
- Page 22 HEAT EXCHANGER Water Temperature to Heat Exchanger Approximate Rated Gallons/minute Maximum Water Pressure Pressure Water Flow Drop @ Maximum Size PSIG 60 F. 70 F. 80 F. 90 F. Flow (PSI) 350 HP 400 HP 500 HP The maximum water flow shown is allowable through the heat exchanger. FIGURE 2–8 –...
- Page 23 The heat exchanger system is designed to operate with pressure is 150 PSIG. If another aftercooler is used, water inlet temperatures from 60 to 90 F and a water consult the manufacturer for operating limits. outlet temperature not to exceed 110 F. If water cooler than 60 F is used, high water outlet temperatures (over 110 F) will be experienced along with shortened heat exchanger life caused by tube fouling and corro-...
- Page 24 to the nearest obstruction on the control box side of the package. Perform all wiring in accordance with the National Elec- Failure to properly ground the com- trical Code (NFPA–70) and any applicable local electri- pressor package could result in con- cal codes.
- Page 25 ELECTRIC MOTOR GREASE RECOMMENDATIONS (–30 to 50 C) MANUFACTURER TRADE NAME CHEVRON SRI #2 SHELL DOLIUM R EXXON UNIREX #2 EXXON POLYREX ELECTRIC MOTOR REGREASING INTERVAL Relubrication Type of Service Typical Examples Rating Interval Standard One– or Two–Shift Operation Above 150 HP 12 Months Severe Continuous Operation...
- Page 26 42, for complete servicing instructions. red “ADD OIL” range. Do not mix different type Be sure the inlet line, if used, is tight and clean. oils. The unit is shipped filled with Gardner Denver AEON 9000 SP Lubricating Coolant which is Coupling –...
- Page 27 System Pressure – Set the controls to the de- Check all screws and latches for tightness. Be sired load pressure. DO NOT EXCEED THE sure doors are closed and latched. MAXIMUM OPERATING PRESSURE ON THE STARTING THE UNIT – Observe the following starting COMPRESSOR NAMEPLATE.
- Page 28 SECTION 4 CONTROLS & INSTRUMENTATION GENERAL DESCRIPTION – The Gardner–Denver CONTROL DEVICES rotary screw compressor is prewired with all controls, motor, and starter for the voltage and horsepower at Controller – This compressor unit features the ”AUTO the time of ordering. It is necessary only to connect the SENTRY ”...
- Page 29 302ETY797–A (Ref. Drawing) FIGURE 4–1 – SCHEMATIC TUBING DIAGRAM...
- Page 30 FIGURE 4–3 – MINIMUM DISCHARGE PRESSURE VALVE The valve incorporates an orifice which, when air is flowing through it, maintains pressure in the oil reser- voir. A spring–loaded piston valve senses air pressure on the upstream (reservoir) side of the valve. When the FIGURE 4–2 –...
- Page 31 203EAU797–A (Ref. Drawing) FIGURE 4–4 – INLET 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 allow the one with the highest pressure to pass through. The shuttle valve is used to provide control air pressure from either the reservoir or plant air system, as required during differ- ent operating conditions.
- Page 32 System Pressure Transducer – This transducer is connected after the minimum pressure valve. It con- verts the pressure in the plant air system into an electri- cal signal for use by the “AUTO SENTRY ” controller for modulation and control. Reservoir Pressure Transducer –...
- Page 33 FIGURE 4–7 – TURN VALVE ACTUATOR is exhausted to the compressor inlet cavity, causing the Fan Starter – The starter is used to provide control turn valve to move towards the full load position. If TVO and overload protection for the package fan. Overload only is energized, the top of the turn valve actuator is heaters should be selected and adjusted based on the exhausted to the compressor inlet cavity, causing the...
- Page 34 304ETY797–A (Ref. Drawing) FIGURE 4–8 – CONTROL SCHEMATIC – COMPRESSOR AT FULL LOAD...
- Page 35 305ETY797–A (Ref. Drawing) FIGURE 4–9 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – CONSTANT SPEED MODE...
- Page 36 306ETY797–A (Ref. Drawing) FIGURE 4–10 – CONTROL SCHEMATIC – COMPRESSOR FULLY UNLOADED – LOW DEMAND MODE...
- Page 37 302ETY546 (Ref. Drawing) FIGURE 4–11 – WIRING DIAGRAM...
- Page 38 RECOMMENDED LUBRICANT – Gardner Denver compressors are factory filled with AEON lubricants. These lubricants are formulated to the highest quality standards and are factory authorized, tested and ap- proved for use in rotary screw compressors.
- Page 39 303ETY797–A (Ref. Drawing) FIGURE 5–1 – FLOW DIAGRAM...
- Page 40 307ETY797–A (Ref. Drawing) OIL PIPING FOR REMOTE COOLER FIGURE 5–2 – OIL FLOW DIAGRAM – REMOTE OVERHEAD MOUNTED 13–13–600 Page 32...
- Page 41 Air/oil under pressure will cause All materials used in Gardner Denver severe personal injury or death. Shut compressor units are compatible with down compressor, relieve system of AEON 9000 SP Lubricating Coolant. all pressure, disconnect, tag and Use caution when selecting down-...
- Page 42 Subsequent lubricant changeouts should be at Gardner Denver offers a free oil analysis program normal intervals. (See “Oil Change Interval” and with the AEON lubricants and we recommend a sam- chart below.)
- Page 43 To drain the system, use one of the following methods: Be sure the unit is completely off and that no air pressure is in the oil reservoir. If the unit is not elevated high enough to use the Disconnect, tag and lockout the power supply to oil reservoir drain line to drain oil, a small hand, the starter.
- Page 44 moves dirt and abrasives from the circulated oil. The oil Use the following procedure to replace the filter. Do not filter relief valves are located in the top manifold of the disturb the piping. filterstat. To replace, unbolt the manifolds and remove valves.
- Page 45 pressure gauges at fittings in the inlet and outlet oil pip- valve must come from the line between the tee and the ing near the end of the cooler. At normal operating air orifice in the blowdown muffler line. When the machine service pressures (65 to 150 psig), with the unit warm, blows down, it will activate the pneumatic valve which a pressure drop of 2 to 25 psig can be expected be-...
- Page 46 It is mandatory that any water cooled unit be installed in a shelter heated to temperatures above freezing (32 F, 0 C. COMPRESSOR OIL COOLER – WATER–COOLED HEAT EXCHANGER (FIGURE 5–1, page 31) – The heat exchanger oil cooler is a multiple pass type, with water in the tubes and oil in the shell.
- Page 47 FIGURE 5–6 – DEW POINT TEMPERATURE VS. AMBIENT TEMPERATURE (100% RELATIVE HUMIDITY) and placed so that damage will not occur in normal maintenance or traffic past the unit. If the leak develops through the packing, tighten the packing gland nut firmly with a wrench to reseat the packing around the valve stem, then back off the nut until loose, and finally retighten the nut finger tight.
- Page 48 newable cartridge–type separator element and pro- vides the final removal of oil from the air stream (FIGURE 5–7, page 39). A sudden drop of zero pressure differ- Oil impinging on the outside of the separator element ential or sudden heavy oil carryover drains directly back into the oil reservoir by gravity.
- Page 49 Lift the separator from the separator housing. Compressor Oil Inlet Temperature – 150 to 160 F (66 to 71 C) – Install a tee at the oil filter outlet and Inspect and/or replace separator check with a thermometer. necessary. Before installing (or reinstalling) any Oil Inlet Pressure –...
- Page 50 Never use elements that are damaged, ruptured or wet. Never use gaskets that won’t seal. Keep spare Use only genuine Gardner Denver air elements and gaskets on hand to re- filter elements on Gardner Denver duce downtime. Store elements in a compressor units.
- Page 51 Pressure drop through a filter with a freshly tube when required by ramming a clean dry cloth cleaned element is below three (3) inches (76 through the tube. Wipe the inside of the filter body to mm) of water with the compressor running at full remove any dirt falling from the inlet tube before rein- load –...
- Page 52 SECTION 7 COUPLING (17 N–M) (37 N–M) (1.6 mm to 3.2 mm) FIGURE 7–1 – INSTALLATION OF COUPLING CUSHIONS Working through the coupling guard opening, cen- ter the coupling over the gap between the shafts, maintaining the gap as shown in FIGURE 7–1 be- tween the ends of the jaws on one coupling body Rotating machinery...
- Page 53 SECTION 8 MAINTENANCE SCHEDULE SERVICE CHECK LIST – Air Filter – Operating conditions determine frequency Every 125 Hours Operation of service. If the “CHANGE AIR FILTER” message is Check for dirt accumulation on oil/aftercooler core displayed, air filter requires servicing or changing. See faces and the cooling fan.
- Page 54 SECTION 9 TROUBLE SHOOTING SYMPTOM POSSIBLE CAUSE REMEDY Compressor fails to start. 1. Wrong lead connections. 1. Change leads. 2. Blown fuses in control 2. Replace fuse. box. 3. Motor starter overload 3. Reset and investigate heaters tripped. cause of overload. 4.
- Page 55 SYMPTOM POSSIBLE CAUSE REMEDY Compressor is low on 1. Restricted air filter. 1. Clean or replace filter. delivery and pressure. 2. Sticking inlet valve. 2. Inspect and clean inlet valve. 3. Unload pressure adjusted 3. Adjust the unload pressure. too low. See manual 13–9/10–647.
- Page 56 9. Check oil reservoir tempera– ture and if low, change thermal mixing valve element to higher temperature. Gardner Denver factory remanufactured replacement compressor air end units are available from your authorized distributor, on an exchange basis, for all rotary screw compressor units. 13–13–600...
- Page 57 Company’s judgment is proved not to be as warranted. Gardner Denver Machinery Inc. (the “Company”) war- Labor shall be limited to the amount specified in the rants to each original retail purchaser (“Purchaser”) of Company’s labor rate schedule.
- Page 58 Specifications subject to change without notice. Copyright 1998 Gardner Denver Machinery Inc.